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:

Alternator Rotor Installation
Using a cleaning fluid, clean off any oil or dirt on the following portions and dry them with a clean cloth. Crankshaft Tapered Portion [A] Alternator Rotor Tapered Portion [B] Install the alternator rotor. Using a cleaning fluid, clean off any oil or dirt on the washer [A] ...

Mode-switching
Depress the S-KTRC button on the left handlebar switch to change the mode. The mode can be changed only when the throttle grip is closed completely. The S-KTRC OFF can be selected only when the motorcycle is at a stop. Changing to mode 1 from S-KTRC OFF is possible while riding. NOTE ...

Oil Pump Installation
Install the outer rotor [A] into the crankcase. Assemble: Oil (Water) Pump Shaft [B] Pin [C] Inner Rotor [D] To prevent dropping, apply grease to the pin. Install the inner rotor assembly into the crankcase. Fit the slot [E] onto the projection [F]. Replace the O-ring [A ...