Kawasaki Ninja Service Manual: Radiator Cap Inspection

Kawasaki Ninja Service Manual / Cooling System / Radiator / Radiator Cap Inspection

Remove: Radiator Cap (see Coolant Change in the Periodic Maintenance chapter)
Check the condition of the bottom [A] and top [B] valve seals and valve spring [C].

If any one of them shows visible damage, replace the cap with a new one.

Radiator Cap Inspection

Install the cap [A] on a cooling system pressure tester [B].

NOTE

Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.

Radiator Cap Inspection

Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward. Stop pumping and measure leak time at once. The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds.

Radiator Cap Relief Pressure Standard: 112 ∼ 142 kPa (1.14 ∼ 1.45 kgf/cm², 16 ∼ 21 psi)

If the cap can not hold the specified pressure or if it holds too much pressure, replace it with a new one.

Radiator Inspection

Remove the radiator (see Radiator and Radiator Fan Removal). Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully s ...

Radiator Filler Neck Inspection

Remove: Radiator Cap (see Coolant Change in the Periodic Maintenance chapter) Check the radiator filler neck for signs of damage. Check the condition of the top and bottom sealing seats [ ...

Other materials:

Crankcase Assembly
NOTICE The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. With a high flash-point solvent, clean off the mating surfaces of the crankcase halves and wipe dry WARNINGGasoline and low flash-poin ...

Front Fork Installation (Each Fork Leg)
Install the fork so that the top plug end [A] as shown in the figure. 11 mm (0.43 in.) [B] Steering Stem Head [C] Tighten: Torque - Front Fork Clamp Bolts (Lower): 23 N·m (2.3 kgf·m, 17 ft·lb) NOTE Tighten the two lower front fork clamp bolts alternately two times to ensur ...

Camshaft Runout Inspection
Remove the camshafts (see Camshaft Removal). Set the camshaft in a camshaft alignment jig or on V blocks. Measure the runout with a dial gauge at the specified place as shown in the figure. If the runout exceeds the service limit, replace the camshaft. Camshaft Runout Standard: TIR ...