Kawasaki Ninja Service Manual: Alternator Cover Installation

Kawasaki Ninja Service Manual / Electrical System / Charging System / Alternator Cover Installation

Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth.
Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount.

Sealant - Liquid Gasket, TB1211F: 92104-0004

Check that dowel pins [B] are in place on the crankcase.

Alternator Cover Installation

Replace the alternator cover gasket with a new one.
Install the alternator cover [A] and the clamps [B].

Fit the upper clamp to the side [C] of the alternator cover.

Fit the lower clamp to the stopper [D] of the alternator cover.

Tighten: Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Connect the alternator lead connector and run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Alternator Cover Installation

Alternator Cover Removal

Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Bolt [A] ...

Stator Coil Removal

Remove: Alternator Cover (see Alternator Cover Removal) Holding Plate Bolt [A] and Plate [B] Alternator Lead Grommet [C] Stator Coil Bolts [D] Remove the stator coil [E] from the alternat ...

Other materials:

Special Tools
Bearing Driver Set: 57001-1129 Jack: 57001-1238 Bearing Remover Head, 25 × 28: 57001-1346 Bearing Remover Shaft, 13: 57001-1377 Jack Attachment: 57001-1608 ...

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 ...

Nozzle Assy Disassembly
Remove the nozzle assy (see Nozzle Assy Removal). Pull out the secondary fuel injectors [A] from the delivery pipe assy [B]. NOTE Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. NOTICE Never drop the secondary fuel injecto ...