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:

Handlebar Installation
Apply a non-permanent locking agent to the threads of the handlebar positioning bolts and tighten them. Torque - Handlebar Positioning Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Install the steering stem head with handlebars. Install the washer [A] and steering stem head nut [B]. Tighten: ...

ECU Power Supply Inspection
Remove the upper air cleaner housing (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). Visually inspect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Remove the ECU (see ECU Removal). Visually inspect the ...

Relay Box Removal
Remove the left fuel tank cover (see Fuel Tank Removal in the Fuel System (DFI) chapter). Disconnect the connectors [A]. Pull out the relay box [B] from the rubber protector [C]. NOTE The relay box has relays and diodes. The relays and diodes can not be removed. Relay Box Installa ...