Kawasaki Ninja Service Manual: Thermostat Installation

Kawasaki Ninja Service Manual / Cooling System / Thermostat / Thermostat Installation

Replace the O-rings [A] with new ones, and apply grease to them.
Assemble: O-rings Thermostat Housing [B] Thermostat [C] Thermostat Cap [D]

Thermostat Installation

Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top.

Tighten: Torque - Thermostat Cap Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
Install the thermostat assembly to the cylinder head.
Tighten: Torque - Thermostat Housing Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Install the removed parts (see appropriate chapters).

Thermostat Installation

Thermostat Removal

Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see T ...

Thermostat Inspection

Remove the thermostat (see Thermostat Removal). Inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. To check valve openi ...

Other materials:

DFI System Troubleshooting Guide
NOTE This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system. The ECU may be involved in the DFI electrical and ignition system tro ...

Sidestand Installation
Replace the sidestand nut [A] with a new one. Apply grease to the sliding areas [B]. Tighten the sidestand bolt [C] first, and then the sidestand nut. Torque - Sidestand Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) Sidestand Nut: 29 N·m (3.0 kgf·m, 21 ft·lb) Install the spring [D] as sh ...

Special Tools
Inside Circlip Pliers: 57001-143 Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 Jack: 57001-1238 Bearing Remover Head, 15 × 17: 57001-1267 Fork Oil Level Gauge: 57001-1290 Bearing Remover Shaft, 13: 57001-1377 Fork Oil Seal Driver, 43: 57001-15 ...