Kawasaki Ninja Service Manual: Alternator Cover Installation

Kawasaki Ninja Service Manual / Electrical System / Charging System / Alternator Cover Installation

Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth.
Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount.

Sealant - Liquid Gasket, TB1211F: 92104-0004

Check that dowel pins [B] are in place on the crankcase.

Alternator Cover Installation

Replace the alternator cover gasket with a new one.
Install the alternator cover [A] and the clamps [B].

Fit the upper clamp to the side [C] of the alternator cover.

Fit the lower clamp to the stopper [D] of the alternator cover.

Tighten: Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Connect the alternator lead connector and run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Alternator Cover Installation

Alternator Cover Removal

Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Bolt [A] ...

Stator Coil Removal

Remove: Alternator Cover (see Alternator Cover Removal) Holding Plate Bolt [A] and Plate [B] Alternator Lead Grommet [C] Stator Coil Bolts [D] Remove the stator coil [E] from the alternat ...

Other materials:

Air Intake Duct Assembly (Other than US, CA and CAL Models)
Install the seals [A] as shown in the figure. Fit the projections [A] of the air intake valve to the hole [B] of the air intake ducts. Tighten: Torque - Air Intake Duct Assembly Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) Hang the shaft [A] to the air intake valve securely ...

Water Temperature Sensor Resistance Inspection
Refer to the Water Temperature Sensor Inspection in the Electrical System chapter. If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter). Water Temperature Sensor Circuit 1. ECU 2. Water T ...

Starter Motor Installation
NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. Clean the starter motor legs [A] and crankcase where the starter motor is ground. Replace the O-ring [A] with a new one. Apply grease to the new O-ring. Tighten: Torque - Starter ...