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:

Brake Disc Installation
Install the brake disc on the wheel so that the marked side [A] faces out. Front Brake Discs [B] Rear Brake Disc [C] Apply a non-permanent locking agent to the threads of the brake disc mounting bolts. Tighten: Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20 ...

Special Tools and Sealants
Outside Circlip Pliers: 57001-144 Piston Pin Puller Assembly: 57001-910 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 79: 57001-1097 Bearing Driver Set: 57001-1129 Liquid Gasket, TB1216B: 92104-1064 Liquid Gasket, TB1207B: 92104-2068 ...

Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect ra ...