Kawasaki Ninja Service Manual: Exhaust Butterfly Valve Cable Removal

Kawasaki Ninja Service Manual / Engine Top End / Muffler / Exhaust Butterfly Valve Cable Removal

Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).
Open the clamp [A] and free the cables.
Slide the dust covers [B].

Exhaust Butterfly Valve Cable Removal

Loosen the locknuts [A], and turn the adjusters [B] to give the cable plenty of play.

Exhaust Butterfly Valve Cable Removal

Remove the clamp [A].
Remove the upper ends [B] of the exhaust butterfly valve cables from the pulley [C].

Exhaust Butterfly Valve Cable Removal

Remove the muffler body cover (see Muffler Body Removal).
Remove the bolt [A] and pulley cover [B].

Exhaust Butterfly Valve Cable Removal

Remove: Clamp [A] Screw [B] and Stopper [C] (ZX1000J model) Bolt [D] (ZX1000J model) Bolts [E] ZX1000J [F] ZX1000K [G]

Exhaust Butterfly Valve Cable Removal

Loosen the locknuts [A].
Remove the lower ends of the exhaust butterfly valve cables from the pulley [B].
Pull the exhaust butterfly valve cables out of the frame.

Exhaust Butterfly Valve Cable Removal

Exhaust Pipe Installation

Replace the exhaust pipe gaskets [A] and premuffler chamber gasket [B] with new ones. Install the premuffler chamber gasket to the premuffler chamber [C] until it is bottomed so that the cham ...

Exhaust Butterfly Valve Cable Installation

Confirm whether pulley [A] is an angle shown in the figure. 41.7° ±7° [B] This position is original position of the pulley. NOTE Correct the position electrically after confirming the u ...

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Coolant Deterioration Inspection
Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). Visually inspect the coolant in the reserve tank [A]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. I ...

Coolant Level Inspection
NOTE Check the level when the engine is cold (room or ambient temperature). Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L” level line [B], remove the upper fairing assembly (s ...

Oil and/or Oil Filter Change
To change the engine oil and replace oil filter, the engine oil drain bolt and oil filter must be removed. The oil change and oil filter replacement should be done by an authorized Kawasaki dealer. A. Engine Oil Drain Bolt A. Oil Filter WARNINGEngine oil is a toxic s ...