Kawasaki Ninja Service Manual: 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)
- 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).
- 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)
- Free the lead from the clamps [A].
- Disconnect the sidestand switch lead connector [B].
- Remove:
Bolt [A]
Heat Insulation Plate [B]
Clear the projections [C] from the frame [D].
- Support the engine with a suitable stand [A].
Put a plank [B] onto the suitable stand for engine balance.
- Remove:
Left Front Engine Mounting Bolt [A]
Middle Engine Mounting Nut [B]
Lower Engine Mounting Nut [C]
- Remove:
Right Front Engine Mounting Bolt [A]
- Using the Hexagon Wrench, turn the adjusting collar [A]
counterclockwise to make the gap between the engine
and adjusting collar.
- 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.
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:
Check 3-3: High Beam Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 3-2.
Connect the terminal [7] to the battery (+) terminal.
Check that the high beam indicator light (LED) [A] goes
on.
If the indicator light does not go on, replace the meter unit.
...
Spring Plate Free Play Measurement
Insufficient clutch free play will cause the engine braking
effect to be more sudden, resulting in rear wheel hop. On
the other hand, if the free play is excessive, the clutch lever
may feel “spongy” or pulsate when pulled.
Hold an extra drive shaft in a vise and install the following
c ...
Air Intake Duct Disassembly
(Other than US, CA and CAL Models)
Remove:
Air Intake Duct (see Air Intake Duct Removal)
Seal [A] and Screen [B]
Turn the air intake valve actuator [C] counterclockwise
(90°).
Remove the shaft [A] of the air intake valve actuator.
Remove:
Pad [A]
Screws [B]
Air Intake Valve [C]
...
Engine Installation