Kawasaki Ninja Service Manual: Radiator Hose and O-ring Replacement
- Drain the coolant (see Coolant Change).
- Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Thermostat Housing [A] (see Thermostat Removal in the
Cooling System chapter)
Oil Cooler [B] (see Oil Cooler Removal in the Engine
Lubrication System chapter)
Water Pump Cover [C] (see Oil Pump Removal in the
Engine Lubrication System chapter)
Fitting [D]
- Replace the hoses [E] and O-rings [F] with new ones.
- Apply grease to the new O-rings.
- Run the new hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
- Tighten:
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
- Install the removed parts (see appropriate chapters).
- Fill the coolant (see Coolant Change).
- Check the cooling system for leaks.
WARNINGCoolant can be extremely hot and cause
severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allo ...
Situate the motorcycle so that it is vertical after warming
up the engine.
Remove the engine oil drain bolt [A] to drain the oil.
The oil in the oil filter can be drained by removing the fil ...
Other materials:
Wiring Diagram (Other than US, CA and CAL with KIBS Models)
ZX1000KC
ZX1000KD
...
Shift Fork/Gear Groove Wear Inspection
Measure the thickness of the shift fork ears [A], and measure
the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard: 5.7 6.0 mm (0.224
0.236 in.)
Service Limit: 5.6 mm ...
Rear Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder
shafts [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and constant
drag on the disc will raise brake and brake fluid temperature.
Check to see that the caliper holder shafts ar ...
Coolant Change
Engine Oil Change