Kawasaki Ninja Service Manual: Oil Pan Installation

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

If the oil filter holder bolt [A] was removed, tighten it.

Apply a non-permanent locking agent to the threads of the oil filter holder bolt.

Torque - Oil Filter Holder Bolt: 35 N·m (3.6 kgf·m, 26 ft·lb)

Replace the O-rings [B] with new ones, and apply grease to them.
Install the O-rings to the oil pipe [C].

Oil Pan Installation

Install: Oil Pressure Relief Valve (see Oil Pressure Relief Valve Installation) Oil Pipe [A] Oil Pipe Holder [B]
Apply a non-permanent locking agent to the oil pipe holder bolt [C].
Tighten: Torque - Oil Pipe Holder Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Oil Pan Installation

Clean the oil screen [A] with a high flash-point solvent and remove any particles stuck to them.

Blow away the particles by applying compressed air [B] from the inside to the outside (from the clean side to the dirty side).

Oil Pan Installation

WARNING

Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the screen in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the screen.

NOTE

While cleaning the oil screen, check for any metal particles that might indicate internal engine damage.

Check the screen carefully for any damage, holes, broken wires.

If the screen is damaged, replace it.

Install the fitting [A] until it is bottomed.

Face the flanged side [B] to the bottom.

Lower Crankcase [C]

Install the hose [D] and the clamp [E].

Face the knob of the clamp [F] inward as shown in the figure.

Viewed from Bottom [G]

Oil Pan Installation

Replace the O-rings [A] [B] with new ones, and apply grease to them.
Install the O-rings.

Turn the chamfered side [C] downward.

Install the oil screen [D].

Fit the claws [E] to the crankcase rib [F].

Oil Pan Installation

Replace the oil pan gasket [A] with a new one.
Install the clamp [B] as shown in the figure.
Tighten the oil pan bolts [C] as shown sequence [1 ∼ 18] in the figure.

Torque - Oil Pan Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Front [D]

Oil Pan Installation

Oil Pan Removal

Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Filter (see Oil Filter Repl ...

Oil Pressure Relief Valve

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Other materials:

Fuse Inspection
Remove the fuse. Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. ...

Muffler Body Installation
Replace the muffler body gasket [A] with a new one. Install the muffler body gasket to the premuffler chamber [B] until it is bottomed so that the chamfer side faces premuffler chamber. Install the muffler body clamp [C] as shown in the figure. Insert the projection [D] into the slot [ ...

Alternator Rotor Installation
Using a cleaning fluid, clean off any oil or dirt on the following portions and dry them with a clean cloth. Crankshaft Tapered Portion [A] Alternator Rotor Tapered Portion [B] Install the alternator rotor. Using a cleaning fluid, clean off any oil or dirt on the washer [A] ...