Kawasaki Ninja Service Manual: Air Cleaner Housing Removal

Kawasaki Ninja Service Manual / Fuel System (DFI) / Air Cleaner / Air Cleaner Housing Removal

Remove the fuel tank (see Fuel Tank Removal).
Disconnect the secondary fuel hose [A] from the delivery pipe of the nozzle assy [B] (see Fuel Hose Replacement in the Periodic Maintenance chapter).
Disconnect the secondary fuel injector connectors [C].
Free the lead from the grooves [D].

Air Cleaner Housing Removal

Remove the bolts [A].
For ZX1000JD/KD, remove the ESD ECU from the air cleaner housing.

Air Cleaner Housing Removal

Remove: Clamp [A] Connector [B] Screws [C] Upper Air Cleaner Housing [D] Bolt [E]

Air Cleaner Housing Removal

Remove: ECU (see ECU Removal) Air Cleaner Element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter)
Disconnect: Air Cleaner Drain Hose [A] Breather Hose [B]

Air Cleaner Housing Removal

Loosen the air cleaner housing clamp bolts [A].
Disconnect the hose [B].

Air Cleaner Housing Removal

Separate the air switching valve hose [A] from the lower air cleaner housing [B].

Air Cleaner Housing Removal

Air Cleaner Oil Draining

A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. Visually check the drain hose [A] if the water or oil accumulates. If any wate ...

Air Cleaner Housing Installation

For ZX1000JD/KD, be sure to install the pad [A]. Install the clamp bolt heads [A] inside as shown in the figure. Install the air cleaner housing on the throttle body assy. Push in ...

Other materials:

Fuel Tank and Cap Inspection
Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank and drain it ...

Water Temperature Sensor Output Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). Disconnect the water temperature sensor connector and connect the measuring adapter [A] between these connectors ...

Brake Pedal Installation
Apply grease to the brake pedal pivot shaft [A]. Install: Washers [B] Brake Pedal [C] Apply a non-permanent locking agent to the threads of the brake pedal mounting bolt [D], and tighten it. Torque - Brake Pedal Mounting Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) Install the re ...