Kawasaki Ninja Service Manual: Fuel Hose Replacement

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Replacement Parts / Fuel Hose Replacement

Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).

WARNING

Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage.

For Primary Fuel Hose (Fuel Tank Throttle Body Assy)

Free the fuel hose from the clamp.
Be sure to place a piece of cloth around the fuel hose joint.
Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush.

For Primary Fuel Hose (Fuel Tank Throttle Body Assy)

When removing with standard tip screwdriver

Insert the standard tip screwdriver [A] into the slit on the joint lock [B].
Turn the driver to disconnect the joint lock.

When removing with fingers

Open and push up [C] the joint lock with your fingers.

When removing with fingers

NOTICE

Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing.

Pull the fuel hose out of the pipe.
Cover the delivery pipe with the vinyl bag to keep it clean.
Remove the vinyl bag on the pipe.
Check that there are no flaws, burrs, and adhesion of foreign materials on the delivery pipe [A].

When removing with fingers

Replace the fuel hose [A] with a new one.

The fuel hose in Brazil model has yellow paint [B].

Install the rubber clamp [C] to the fuel hose as shown in the figure.
Hook the rubber clamp to the clamp of the frame ground terminal (see Cable, Wire, and Hose Routing section in the Appendix chapter).

When removing with fingers

Apply engine oil to the pipe.
Run the fuel hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Check the yellow paint of the fuel hose in the throttle body assy side (Brazil model only).

Insert the fuel hose joint [A] straight onto the delivery pipe [B] until the hose joint clicks.
Push the joint lock [C].

When removing with fingers

Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and does not come off.

When removing with fingers

WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

For Secondary Fuel Hose (Throttle Body Assy Nozzle Assy)

Be sure to place a piece of cloth around the fuel hose joint.
Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush.

For Secondary Fuel Hose (Throttle Body Assy Nozzle Assy)

When removing with standard tip screwdriver

Insert the standard tip screwdriver [A] into the slit on the joint lock [B].
Turn the driver to disconnect the joint lock.

When removing with fingers

Open and push up [C] the joint lock with your fingers.

When removing with fingers

NOTICE

Pull the fuel hose out of the pipe.
Cover the delivery pipe with the vinyl bag to keep it clean.
Remove the vinyl bag on the pipe.
Check that there are no flaws, burrs, and adhesion of foreign materials on the delivery pipe [A].

When removing with fingers

Replace the fuel hose [A] with a new one.

The fuel hose in Brazil model has yellow paint [B].

When removing with fingers

Apply engine oil to the pipe.
Insert the fuel hose joint [A] securely onto the delivery pipe [B] until the hose joint clicks.
Push the joint lock [C].

Check the yellow paint of the fuel hose in the throttle body assy side (Brazil model only).

When removing with fingers

Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and does not come off.

WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

When removing with fingers

Insert [A] the fuel hose joint [B] straight onto the delivery pipe until the hose joint clicks.
Push [C] the joint lock [D].

When removing with fingers

NOTICE

When inserting the fuel hose joint, do not apply strong force to the delivery pipe [E] on the nozzle assy. The pipe made from resin could be damaged.

Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and does not come off.

NOTICE

When pushing and pulling the fuel hose joint, do not apply strong force to the delivery pipe [C] on the nozzle assy. The pipe made from resin could be damaged.

Fuel Hose Replacement

WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

Install the fuel tank (see Fuel Tank Installation in the Fuel System (DFI) chapter).
Start the engine and check the fuel hose for leaks.

Air Cleaner Element Replacement

NOTE In dusty areas, the element should be replaced more frequently than the recommended interval. WARNINGIf dirt or dust is allowed to pass through into the throttle body assy, the t ...

Coolant Change

WARNINGCoolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allo ...

Other materials:

Fuel Hose Inspection (fuel leak, damage, installation condition)
If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hoses. Replace the fuel hose if any fraying, cracks [B] or ...

Crankshaft Sensor Peak Voltage Inspection
NOTE Be sure the battery is fully charged. Using the peak voltage adapter [A] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements. Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor ...

Inner Tube Inspection
Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is replaced. NOTICE If the inner tube is badly bent or creased, replace it. Excessive bending, followed by ...