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 ...

Other materials:

Transmission Assy Removal
Remove: Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Gear Position Switch (see Gear Position Switch Removal in the Electrical System chapter) Collar [A] O-ring [B] Remove: Clutch (see Clutch Removal in the Clutch chapter) Shift Shaft Assembly ...

Torque Limiter Installation
Apply molybdenum disulfide grease to the torque limiter shaft [A]. Install the torque limiter [B], the collar [C] and the shaft. Turn the large-hole end of the shaft to inside as shown in the figure. Replace the washer [D] with a new one. Apply a non-permanent locking agent to the t ...

ESD (Electronic Steering Damper) ECU Removal (ZX1000JD/KD)
NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. Lift up the front portion of the fuel tank, and hold it with a suitable bar or block (see Fuel Tank Removal in the Fuel System (DFI) chapter). NOTE When removing the ESD ECU only, there ...