Kawasaki Ninja Service Manual: Engine Removal

Kawasaki Ninja Service Manual / Engine Removal/Installation / Engine Removal/Installation / Engine Removal

Support the rear part of the swingarm with a stand.
Squeeze the brake lever slowly and hold it with a band [A].

WARNING

Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.

NOTICE

Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.

Drain: Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Coolant (see Coolant Change in the Periodic Maintenance chapter)
Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clutch Cable Lower End (see Cable Removal in the Clutch chapter) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Premuffler Chamber (see Premuffler Chamber Removal in the Engine Top End chapter) Shift Lever (see Shift Pedal Removal in the Crankshaft/ Transmission chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter)

Engine Removal

Disconnect: Gear Position Switch/Sidestand Switch Lead Connector [A] Crankshaft Sensor/Oil Pressure Switch Lead Connector [B] Stick Coil Connectors (see Stick Coil Removal in the Electrical System chapter)
Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).

Engine Removal

Remove the engine ground cable terminal bolt [A].
Disconnect: Water Temperature Sensor Connector [B] Starter Motor Cable [C] (see Starter Motor Removal in the Electrical System chapter)

Engine Removal

Free the lead from the clamps [A].
Disconnect the sidestand switch lead connector [B].

Engine Removal

Remove the clamps [A].

Engine Removal

Remove: Bolt [A] Heat Insulation Plate [B] Clear the projections [C] from the frame [D].

Engine Removal

Support the engine with a suitable stand [A].

Put a plank [B] onto the suitable stand for engine balance.

Engine Removal

Remove: Left Front Engine Mounting Bolt [A] Middle Engine Mounting Nut [B] Lower Engine Mounting Nut [C]

Engine Removal

Remove: Right Front Engine Mounting Bolt [A]

Engine Removal

Using the nut wrench [A], loosen the locknut [B].

Special Tool - Engine Mount Nut Wrench: 57001-1450

Engine Removal

Using the Hexagon Wrench, turn the adjusting collar [A] counterclockwise to make the gap between the engine and adjusting collar.

Engine Removal

Turn the middle and lower engine mounting bolts clockwise to make the gap between the adjusting collar and frame.
Pull out the engine mounting bolts.
Using the stand, take out the engine.

Engine Installation

Apply molybdenum disulfide grease to the threads of the adjusting collars [A]. Install the adjusting collars to crankcase backside until end of the threads. Install the adjusting co ...

Other materials:

Fuel Pressure Inspection
NOTE Be sure the battery is fully charged. Remove: Fuel Tank Covers (see Fuel Tank Removal) Fuel Tank Bolts (see Fuel Tank Removal) Primary Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Be sure to place a piece of cloth around the fuel outlet pipe of the ...

Idle Speed Inspection
Start the engine and warm it up thoroughly. With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged. Be sure to correct any of these conditions before rid ...

Backups
The ECU takes the following measures to prevent engine damage when the DFI, ignition, S-KTRC or immobilizer system parts have troubles. Note: (1): D-J Method: When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating fr ...