Kawasaki Ninja Service Manual: Fuel Tank Removal

• Turn the ignition switch to OFF.
• Wait until the engine cools down.
• Remove: Front Seat (see Front Seat Removal in the Frame chapter)
• Open the fuel tank cap [A] to lower the pressure in the tank.

During tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less.

• Draw the fuel out from the fuel tank with a commercially available pump [A].

Use a soft plastic hose [B] as a pump intake hose in order to insert the hose smoothly.

Put the hose through the fill opening [C] into the tank and draw the fuel out.

Front [D]

• Remove: Bolts [A] Fuel Tank Covers (Both Sides) [B]

Clear the hook fastener [C], projections [D] and hook portion [E].

Remove the relay box [A] from the left fuel tank cover [B].

• Remove: Bolts (Both Sides) [A] Upper Fuel Tank Cover [B]

Clear the projections [C] from the holes.

• Remove: Fuel Tank Bolts (Both Sides) [A] Fuel Tank Bracket Bolts [B]

• Lift up the front portion of the fuel tank, and then disconnect the hoses [A].
• For the California and Southeast Asia models, disconnect the following.

  Fuel Return Hose

• Disconnect: Battery (–) Terminal Fuel Pump Lead Connector [A]

• Be sure to place a piece of cloth around the fuel hose joint.
• Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush.

When removing with standard tip screwdriver

• Insert the standard tip screwdriver [A] into the slit on the joint lock [B].
• Turn the driver to disconnect the joint lock.

When removing with fingers

• Open and push up [C] the joint lock with your fingers.

NOTICE

Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing.

• Pull the fuel hose out of the pipe.
• Cover the delivery pipe with the vinyl bag to keep it clean.

• Close the fuel tank cap.
• Remove the fuel tank, and place a it on a flat surface.

Do not apply the load to the fuel outlet pipe of the fuel pump.

• For the California and Southeast Asia models, note the following.

NOTICE

For the California and Southeast Asia models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.

Be sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal.

If liquid or gasoline flows into the breather hose, remove the hose and blow it clean with compressed air.

Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump.