Kawasaki Ninja Service Manual: Nozzle Assy Installation

Kawasaki Ninja Service Manual / Fuel System (DFI) / Nozzle Assy / Nozzle Assy Installation

Replace the dust seals [A] with new ones.
Apply engine oil to the new dust seals, and install them.
Install the nozzle assy securely.

Push the four mounting positions of the injectors.

Set the joint pipe parallel to the air cleaner housing [B].

NOTICE

When installing the nozzle assy, apply force equally to the delivery pipe assy.

Pushing the fuel pipe strongly could damage it as it is made from resin.

Nozzle Assy Installation

Tighten the mounting bolts as shown sequence [1 ∼ 4] in the figure.

Torque - Nozzle Assy Mounting Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb)

Run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
Connect the secondary fuel hose to the delivery pipe of the nozzle assy (see Fuel Hose Replacement in the Periodic Maintenance chapter).

Nozzle Assy Installation

Nozzle Assy Removal

Remove the fuel tank (see Fuel Tank Removal). Disconnect the secondary fuel hose [A] from the delivery pipe assy of the nozzle assy [B] (see Fuel Hose Replacement in the Periodic Maintenance ...

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 ...

Other materials:

Valve Guide Installation
Apply engine oil to the valve guide outer surface before installation. Heat the area around the valve guide hole to about 120 150°C (248 302°F). NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil. Usin ...

Subthrottle Sensor Output Voltage Inspection
Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection, note the following. Disconnect the subthrottle sensor connector and connect the setting adapter [A] between these connectors. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538 ...

Lower Fairing Removal
Remove the quick rivets [A]. Remove: Quick Rivets [A] Bolts [B] Pull up the core by the flat-head screwdriver (–), and then remove the quick rivet. Clear the hook portions on the upper edges [C] from the slots, and remove the left lower fairing [D]. While pulling down ...