Kawasaki Ninja Service Manual: Engine Installation

Kawasaki Ninja Service Manual / Engine Removal/Installation / Engine Removal/Installation / Engine Installation

Engine Installation


Engine Installation


Put a plank onto the suitable stand for engine balance.

Support the engine until all bolts have been tightened.

First, install and tighten the following bolts temporarily.

Middle Engine Mounting Bolt [A] Lower Engine Mounting Bolt [B] Left Front Engine Mounting Bolt [C] Right Front Engine Mounting Bolt [D]

Engine Installation


Second, tighten the left front engine mounting bolt [A].

Frame [B] Engine [C] Torque - Left Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb)

Third, insert the middle [A] and lower [B] engine mounting bolts to the adjusting collars [C], and tighten the bolts counterclockwise.

NOTE

Tighten the bolts until the clearance [D] between the frame and collar come to 0 mm (0 in.).

Torque - Middle Engine Mounting Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) Lower Engine Mounting Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Fourth, tighten the middle [E] and lower [F] engine mounting nuts.

Engine Installation


Fifth, remove the right front engine mounting bolt [A].

Sixth, tighten the adjusting collar [B] clockwise by hand until the clearance [C] between the engine [D] and collar come to 0 mm (0 in.).

Seventh, tighten the adjusting collar locknut [E].

Special Tool - Engine Mount Nut Wrench: 57001-1450

Torque - Adjusting Collar Locknut: 49 N·m (5.0 kgf·m, 36 ft·lb)

Lastly, tighten the right front engine mounting bolt.

Torque - Right Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb)

Engine Installation


Check that the pad [A] is in place on the heat insulation plate [B].

5 mm (0.20 in.) [C]

Engine Installation


Insert the projections [A] into the holes [B].

Apply a non-permanent locking agent to the threads of the heat insulation plate bolt [C] and tighten it.

Engine Installation


Engine Removal
Support the rear part of the swingarm with a stand. Squeeze the brake lever slowly and hold it with a band [A]. WARNINGMotorcycle may fall over unexpectedly resulting in an acc ...

Crankshaft/Transmission
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Other materials:

Special Tools and Sealant
Compression Gauge, 20 kgf/cm²: 57001-221 Valve Spring Compressor Assembly: 57001-241 Valve Spring Compressor Adapter, 25: 57001-1019 Valve Seat Cutter, 45° - 27.5: 57001-1114 Valve Seat Cutter, 45° - 32: 57001-1115 Valve Seat Cutter, 32° - 28: 57001-1119 Valve Seat Cutter ...

Clutch Cover Removal
Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End (see Cable Removal) Clutch Cover Bolts [A] Turn the release lever [A] counterclockwise as shown, and remove the clutch cover. About 90° [B] ...

Power mode
The Power mode determines the engine power output characteristics and has three settings. The S-KTRC and the Power mode can be set separately. By combining each setting, the rider can get various power feelings to suit riding conditions or individual preference. Mode F (Full Power): The h ...