Kawasaki Ninja Service Manual: DFI Servicing Precautions

Kawasaki Ninja Service Manual / Fuel System (DFI) / DFI Servicing Precautions

There are a number of important precautions that should be followed servicing the DFI system.

DFI Servicing Precautions


Replace the fuel hose if any fraying, cracks or bulges are noticed.

Torque - Oil Filler Plug: Hand-tighten

DFI Servicing Precautions


Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 Extension Tube: 57001-1578 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001- ...

Troubleshooting the DFI System
The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer equipped models), water temperature warning indicator and oil pressure warning indicator. ...

Other materials:

Crankshaft Sensor Peak Voltage Inspection
NOTE Be sure the battery is fully charged. Using the peak voltage adapter [A] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements. Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor ...

Starter Clutch Installation
Replace the O-ring [A] with a new one and apply grease. Apply molybdenum disulfide grease to the starter clutch shaft [B]. Install: Starter Clutch [C] Spacer (Small Diameter) [D] Spacer (Large Diameter) [E] Starter Clutch Shaft Starter Clutch Shaft Holder [F] Turn the O-ring si ...

Oil Pressure Relief Valve Inspection
Remove the oil pressure relief valve (see Oil Pressure Relief Valve Removal). Check to see if the valve [A] slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE Inspect the valve in its assembled stat ...