Kawasaki Ninja Service Manual: Fuel Flow Rate Inspection

Kawasaki Ninja Service Manual / Fuel System (DFI) / Fuel Line / Fuel Flow Rate Inspection

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

NOTE

Be sure the battery is fully charged.

Turn the ignition switch to OFF.
Wait until the engine cools down
Prepare a fuel hose (Special Tool: 57001-1607) and a measuring cylinder.

Special Tool - Fuel Hose: 57001-1607

Open the fuel tank cap [A] to lower the pressure in the tank.
Disconnect the primary fuel hose from the fuel pump (see Fuel Tank Removal).

Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump.

Fuel Line

WARNING

Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.

Connect the prepared fuel hose [A] to the fuel outlet pipe.
Secure the fuel hose with a clamp.
Insert the fuel hose into the measuring cylinder [B].

WARNING

Wipe off spilled out fuel immediately.

Be sure to hold the measuring cylinder vertical.

Fuel Flow Rate Inspection

Close the fuel tank cap.
Turn the engine stop switch to run position.
Turn the ignition switch to ON.

The fuel pump should operate for 3 seconds, and then should stop.

NOTICE

Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged.

Measure the discharge for 3 seconds.

Repeat this operation several times.

Amount of Fuel Flow Standard: 67 mL (2.3 US oz.) or more for 3 seconds

Turn the ignition switch to OFF.

If the fuel flow is much less than the specified, replace the fuel pump (see Fuel Pump Removal/Installation).

Install the fuel tank (see Fuel Tank Installation).
Start the engine and check for fuel leakage.

Fuel Pressure Inspection

NOTE Be sure the battery is fully charged. Remove: Fuel Tank Covers (see Fuel Tank Removal) Fuel Tank Bolts (see Fuel Tank Removal) Primary Fuel Hose (see Fuel Hose Replacement in the Per ...

Fuel Pump

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Other materials:

Bolt and Nut Tightening
In accordance with the Periodic Maintenance Chart, it is very important to check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki dealer for torque values. 1. Clutch Lever Hol ...

Coupling Bearing Installation
Replace the bearing with a new one. Press in the bearing [A] until it is bottomed. Special Tool - Bearing Driver Set [B]: 57001-1129 Pack the bearing with high-temperature grease. Replace the circlip with a new one. Special Tool - Inside Circlip Pliers: 57001-143 Replace the grease se ...

Transmission Assy Removal
Remove: Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Gear Position Switch (see Gear Position Switch Removal in the Electrical System chapter) Collar [A] O-ring [B] Remove: Clutch (see Clutch Removal in the Clutch chapter) Shift Shaft Assembly ...