Kawasaki Ninja Service Manual: Oil Cooler Installation

Kawasaki Ninja Service Manual / Engine Lubrication System / Oil Cooler / Oil Cooler Installation

Replace the O-ring [A] with a new one.
Apply grease to the new O-ring.

Oil Cooler Installation

Install the water hoses and hose clamps [A] as shown in the figure.

Water Hose (About 300 mm, 11.8 in.) [B] Water Hose (About 130 mm, 5.1 in.) [C] Yellow Paint [D]
Tighten: Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m, 27 in·lb)

Oil Cooler Installation

Install the oil cooler [E].
Apply a non-permanent locking agent to the oil cooler mounting bolts.
Tighten the oil cooler mounting bolts by following the sequence numbers [1 ∼ 4].

Torque - Oil Cooler Mounting Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

Run the water hoses properly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
Pour: Coolant (see Coolant Change in the Periodic Maintenance chapter) Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
Install the removed parts (see appropriate chapters).

Oil Cooler Removal

Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Lower Fairings (see Lower Fai ...

Oil Pressure Measurement

Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pres ...

Other materials:

Front Fork Removal (Each Fork Leg)
Loosen the front fork top plug [A] beforehand if the fork leg is to be disassembled. Special Tool - Top Plug Wrench (45 mm) [B]: 57001-1741 NOTE Loosen the top plug after loosening the handlebar clamp bolt [C] and upper front fork clamp bolt [D]. Remove: Upper Fairing Assembly (see Up ...

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 any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. T ...

Bolt and Nut Tightening
In accordance with the Periodic Maintenance Chart, it is very important to check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki dealer for torque values. 1. Clutch Lever Hol ...