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:

ESD (Electronic Steering Damper) ECU Removal (ZX1000JD/KD)
NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. Lift up the front portion of the fuel tank, and hold it with a suitable bar or block (see Fuel Tank Removal in the Fuel System (DFI) chapter). NOTE When removing the ESD ECU only, there ...

Spring Tension Inspection
Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining s ...

Evaporative Emission Control System Inspection (CAL and SEA-B1 Models)
Inspect the canister as follows. Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). Remove the canister [A]. Visually inspect the canister for cracks or other damage. If the canister has any cracks or bad damage, replace it with a new one. NO ...