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:

Vehicle-down Sensor Installation
Be sure to install the rubber dampers [A] and collars [B] on the bracket. The UP mark [A] of the sensor should face upward. WARNINGIncorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain ...

Brake Fluid Level Inspection
Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper lev ...

Hub Bearing Installation
Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. Replace the bearings with new ones. Install the bearings by using the bearing driver set which does not contact the bearing inner race. ...