Kawasaki Ninja Service Manual: Fuel Hose Replacement

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Replacement Parts / Fuel Hose Replacement

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. Cover the hose connection with a clean shop towel to prevent fuel spillage.

For Primary Fuel Hose (Fuel Tank Throttle Body Assy)


For Primary Fuel Hose (Fuel Tank  Throttle Body Assy)


When removing with standard tip screwdriver

When removing with fingers

When removing with fingers


NOTICE

Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing.

When removing with fingers


The fuel hose in Brazil model has yellow paint [B].

When removing with fingers


Check the yellow paint of the fuel hose in the throttle body assy side (Brazil model only).

When removing with fingers


When removing with fingers


WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

For Secondary Fuel Hose (Throttle Body Assy Nozzle Assy)


For Secondary Fuel Hose (Throttle Body Assy  Nozzle Assy)


When removing with standard tip screwdriver

When removing with fingers

When removing with fingers


NOTICE

Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing.

When removing with fingers


The fuel hose in Brazil model has yellow paint [B].

When removing with fingers


Check the yellow paint of the fuel hose in the throttle body assy side (Brazil model only).

When removing with fingers


WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

When removing with fingers


When removing with fingers


NOTICE

When inserting the fuel hose joint, do not apply strong force to the delivery pipe [E] on the nozzle assy. The pipe made from resin could be damaged.

NOTICE

When pushing and pulling the fuel hose joint, do not apply strong force to the delivery pipe [C] on the nozzle assy. The pipe made from resin could be damaged.

Fuel Hose Replacement


WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

Air Cleaner Element Replacement
NOTE In dusty areas, the element should be replaced more frequently than the recommended interval. WARNINGIf dirt or dust is allowed to pass through into the throttle body assy, the t ...

Coolant Change
WARNINGCoolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allo ...

Other materials:

Coolant Level Inspection
NOTE Check the level when the engine is cold (room or ambient temperature). Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L” level line [B], remove the upper fairing assembly (s ...

Relay Box Removal
Remove the left fuel tank cover (see Fuel Tank Removal in the Fuel System (DFI) chapter). Disconnect the connectors [A]. Pull out the relay box [B] from the rubber protector [C]. NOTE The relay box has relays and diodes. The relays and diodes can not be removed. Relay Box Installa ...

Headlight Aiming Adjustment
NOTE Do not turn the bolts [A] because the reflector in the headlight comes off. (In the photo, the headlight unit has been removed for clarity.) NOTE The left adjuster [A] and right adjuster [B] can move the direction of the headlight beam to up, down, left and right by turning each a ...