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:

Brake Hose and Pipe Replacement
NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Brake Hose Fitting Bolt [A] Brake Hose Banjo Bolts [B] Bolt [C] Clamp ...

Chain Slack Adjustment
Remove the cotter pin, and loosen the axle nut. Loosen the left and right chain adjuster locknuts. A. Axle Nut B. Cotter Pin C. Adjuster D. Locknut If the chain is too loose, turn out the left and right chain adjusters evenly. If the chain is too tight, turn in the left ...

Engine Stop Switch Operation Inspection
First Step Set the gear position in the neutral position. Turn the ignition switch to ON. Turn the engine stop switch to stop position [A]. Push the starter button. The engine does not start. If the engine starts, inspect the engine stop switch (see Switch Inspection in the Electri ...