Kawasaki Ninja Service Manual: Pressure Testing

Kawasaki Ninja Service Manual / Cooling System / Coolant / Pressure Testing

Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Radiator Cap [A]

Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.

Install the cooling system pressure tester [A] on the filler neck.

Pressure Testing

NOTE

Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.

Pressure Testing

Build up pressure in the system carefully until the pressure reaches 142 kPa (1.45 kgf/cm², 21 psi).

NOTICE

During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 142 kPa (1.45 kgf/cm², 21 psi).

Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is all right.

If the pressure drops and no external source is found, check for internal leaks. Droplets in the engine oil indicate internal leakage. Check the cylinder head gasket and the water pump.

Remove the pressure tester, replenish the coolant, and install the radiator cap.

Coolant Deterioration Inspection

Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). Visually inspect the coolant in the reserve tank [A]. If whitish cotton-like wafts are observed, aluminum par ...

Cooling System Flushing

Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accu ...

Other materials:

Spring Tension Inspection
Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining s ...

Water Temperature Sensor Inspection
Remove the water temperature sensor (see Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter). Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [C] is submerged. Suspend an accurate thermometer [B] with temperature ...

Gear Position Switch Inspection
NOTE Be sure the transmission and external shift mechanism are good condition. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Disconnect the connector [A]. Set the hand tester [A] to the × 1 kΩ or × 100 Ω range and connect i ...