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:

Crankshaft Sensor Removal
Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Crankshaft Sensor Lead Connector [A] Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Bolts [A] Crankshaft Sensor Cover [B] and Gasket Oil Pressure Switch Terminal [C] ...

Hub Bearing Inspection
Since the hub bearings are made to extremely close tolerances, the clearance can not normally be measured. NOTE Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with new ones. Turn each bearing in the hub back and forth [A] while checki ...

Piston Installation
Apply molybdenum disulfide oil solution to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together Applymolybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above th ...