Kawasaki Ninja Service Manual: Handlebar Installation

Kawasaki Ninja Service Manual / Steering / Handlebar / Handlebar Installation

Apply a non-permanent locking agent to the threads of the handlebar positioning bolts and tighten them.

Torque - Handlebar Positioning Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Install the steering stem head with handlebars.
Install the washer [A] and steering stem head nut [B].
Tighten: Torque - Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 58 ft·lb) Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

NOTE

Tighten the steering stem head bolt before tightening the upper front fork clamp bolts and handlebar clamp bolts.

Handlebar Installation

WARNING

If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death.

Be sure the cables, harnesses and hoses are routed properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Apply adhesive cement to the inside of the left handlebar grip.
Install the left handlebar grip, throttle grip and left/right handlebar weight
Apply a non-permanent locking agent to the threads of the handlebar weight bolts, and tighten them.
Install the left and right switch housings.

Fit the projection [A] into a hole [B] in the handlebar.

Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)

Handlebar Installation

Install the throttle cable tips.
Install the throttle case.

Fit the projection [A] into a hole [B] in the handlebar.

Tighten: Torque - Throttle Case Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)

Handlebar Installation

Install: Clutch Lever Assembly (see Clutch Lever Installation in the Clutch chapter) Front Master Cylinder (see Front Master Cylinder Installation in the Brakes chapter) Steering Damper (see Steering Damper Installation)

Handlebar Removal

Remove: Steering Damper (see Steering Damper Removal) Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] Left Handlebar Grip [E] ...

Other materials:

Evaporative Emission Control System Inspection (CAL and SEA-B1 Models)
Inspect the canister as follows. Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). Remove the canister [A]. Visually inspect the canister for cracks or other damage. If the canister has any cracks or bad damage, replace it with a new one. NO ...

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 ...

Engine Sprocket Installation
Replace the sprocket washer and axle cotter pin. Install the engine sprocket onto the output shaft. Apply molybdenum disulfide oil solution to the threads and seating surface of the engine sprocket nut. Tighten: Torque - Engine Sprocket Nut: 145 N·m (14.8 kgf·m, 107 ft·lb) NOTE ...