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:
Lighting System
This motorcycle adopt the daylight system and have a
headlight relay in the relay box. The headlight does not
go on when the ignition switch and the engine stop switch
are first turned on. The headlight comes on after the starter
button is released and stays on until the ignition switch is
turn ...
Front Brake Pad Installation
Check that the pad spring [A] is in place on the caliper.
Push the caliper pistons in by hand as far as they will go.
Install the brake pads [A] on the pad spring correctly.
Fit the pad into the groove of the caliper as shown in the
figure.
Install the pad pins while pushing t ...
Intake Air Pressure Sensor #1 Removal
NOTICE
Never drop the intake air pressure sensor #1 especially
on a hard surface. Such a shock to the sensor
can damage it.
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Intake Air Pressure Sensor #1 Connector [A]
Remove the intake air ...