Kawasaki Ninja Service Manual: Premuffler Chamber Installation

Kawasaki Ninja Service Manual / Engine Top End / Muffler / Premuffler Chamber Installation

Replace the premuffler chamber gasket [A] with a new one.
Install the premuffler chamber gasket to the premuffler chamber [B] until it is bottomed so that the chamfer side faces exhaust pipe [C].
Install the exhaust pipe clamp [D] as shown in the figure.
Insert the projection [E] into the slot [F].
Install the premuffler chamber.
Tighten the mounting bolt [G] and clamp bolt [H] securely.

Torque - Premuffler Chamber Mounting Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)

Premuffler Chamber Installation

Install the removed parts (see appropriate chapters).
Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts.

Premuffler Chamber Removal

Remove: Muffler Body (see Muffler Body Removal) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Front Seat (see Front Seat Removal in the Frame chapter) Oxygen Sensor ...

Exhaust Pipe Removal

Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Exhaust Pipe Clamp Bolt [A] (Loosen) Remove the exhaust pipe holder nuts [A], and pull out the ...

Other materials:

Oil Pump Drive Gear Installation
Install is the reverse of removal. Note the following. First, engage the oil pump chain [A] to the gears, and then install the oil pump drive gear [B]. Turn the “OUT” mark [C] to outside. Apply a non-permanent locking agent to the oil pump drive chain guide bolt and the oil pump drive ...

Radiator Hose and O-ring Replacement
Drain the coolant (see Coolant Change). Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Thermostat Housing [A] (see Thermostat Removal in the Cooling System chapter) Oil Cooler [B] (see Oil Cooler Removal in the Engine Lubrication System chap ...

Rocker Arm Removal
Squeeze the brake lever slowly and hold it with a band. Remove the front footpeg bracket bolts. Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal). Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 Remove: Lower Rear Shock Absorber B ...