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:

Sidestand Switch Operation Inspection
Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). Inspect the sidestand switch [A] operation accordance to below table. Sidestand Switch Operation If the sidestand switch operation does not work, inspect or replace the foll ...

Intake Air Pressure Sensor #1 Removal
NOTICE Never drop the intake air pressure sensor #1 especially on a hard surface. Such a shock to the sensor can damage it. Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Intake Air Pressure Sensor #1 Connector [A] Remove the intake air ...

Outline
When a problem occurs with DFI system, the warning indicator light (LED) [A] and FI warning symbol [B] goes on to alert the rider. In addition, the condition of the problem is stored in the memory of the ECU. For models equipped with an immobilizer system, the warning indicator light (LED) and ...