Kawasaki Ninja Service Manual: Throttle Body Assy Removal

Kawasaki Ninja Service Manual / Fuel System (DFI) / Throttle Body Assy / Throttle Body Assy Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

NOTICE

Never drop the throttle body assy especially on a hard surface. Such a shock to the body assy can damage it.

Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Primary and Secondary Fuel Hoses (see Fuel Hose Replacement in the Periodic Maintenance chapter)
Disconnect: Idle Speed Control Valve Actuator Connector [A] Intake Air Pressure Sensor #2 Connector [B] Subthrottle Valve Actuator Connector [C] Intake Air Pressure Sensor #1 Connector [D] Hose [E] (Other than US, CA and CAL Models)
For the California and Southeast Asia models, pull off the vacuum hose.

Throttle Body Assy Removal

Disconnect: Primary Fuel Injector Connectors [A]

Throttle Body Assy Removal

Remove the caps [A] on both sides.

Throttle Body Assy Removal

Loosen the throttle body assy holder clamp bolts [A].

Throttle Body Assy Removal

Remove the throttle body assy [A] from the throttle body assy holders.
Disconnect: Main Throttle Sensor Connector [B] Subthrottle Sensor Connector [C]

Throttle Body Assy Removal

Remove: Clamp [A] Throttle Cable Lower Ends [B]
After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders.

Throttle Body Assy Removal

NOTICE

If dirt gets into the engine, excessive engine wear and possible engine damage will occur.

Throttle Body Assy

Idle Speed Inspection Refer to the Idle Speed Inspection in the Periodic Maintenance chapter. Synchronization Inspection/Adjustment Refer to the Engine Vacuum Synchronization Inspection in the P ...

Throttle Body Assy Installation

Apply a thin coat of grease to the throttle cable lower ends. Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley. Install the clamp [C] securely. ...

Other materials:

Radiator and Radiator Fan Removal
Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Coolant Reserve Tank (see Coolant R ...

Front Fender Removal
Remove: Bolts [A] with Washers (Both Sides) Reflectors (Both Sides, US, CA, CAL and AU Models) Front Fender [B] Take the brake hose off the clamp [C] (both sides). Front Fender Installation Apply a non-permanent locking agent to the front fender mounting bolts. Tighten: ...

Throttle Control System Inspection
Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 2 3 mm (0.08 0.12 in.) Check that the throttle grip [B] moves smoothly from full open to close, and the throttle closes quickly and completely by the ...