Kawasaki Ninja Service Manual: Fuel Tank Installation

Kawasaki Ninja Service Manual / Fuel System (DFI) / Fuel Tank / Fuel Tank Installation

If the dampers are damaged or deteriorated, replace them.

Fuel Tank Installation


Fuel Tank Installation


Install the pad [A], hooks [B] and trim [C] on the fuel tank as shown in the figure.

[D] Attach the pad on the fuel tank so that it covers entire round from end to end.

[E] View N [F] Attach the hook parallel to this line.

[G] View L [H] Attach the hook so that the corner of it contacts the bracket.

[I] Front [J] View M [K] After installation, fix the rear end of the trim to the fuel tank by hand.

Fuel Tank Installation


To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground.

Connect the hoses according to the diagram of the evaporative emission control system. Make sure they do not get pinched or kinked.

Run the hoses with a minimum of bending so that the air or vapor will not be obstructed.

Fuel Tank Installation


Fuel Tank Installation


WARNING

Leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint.

If it comes off, reinstall the hose joint.

Fuel Tank Installation


Fuel Tank Installation


Insert the projections [A] of the upper fuel tank cover [B] into the holes [C] of the fuel tank.

Fuel Tank Installation


Insert the hook portion [A] of the fuel tank into the slot [B] of the fuel tank cover.

Insert the projections [C] into the holes [D], and then attach the hook fastener [E] to the hook fastener [F] on the fuel tank.

Fuel Tank Installation


Fuel Tank Removal
WARNINGGasoline 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 ...

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 n ...

Other materials:

Rear Master Cylinder Installation
Replace the washers that are on each side of hose fitting with new ones. Install the brake hose [A]. Touch the brake hose to the stopper [B] of the rear master cylinder. Tighten: Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) Install the master cylinder, the brack ...

Balancer Installation
Position the crankshaft at #2, 3 positions TDC or at #1, 4 positions TDC. Install the balancer assembly as follows. Align the punch mark [A] on the weight and the projection [B] on the crankcase. Engage the balancer gear and the crankshaft gear. Insert the balancer shaft until it is bot ...

Wheel Rotation Sensor Rotor Inspection
Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] Front Wheel [C] Rear Wheel [D] Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the ...