Kawasaki Ninja Service Manual: Thermostat Installation

Kawasaki Ninja Service Manual / Cooling System / Thermostat / Thermostat Installation

Replace the O-rings [A] with new ones, and apply grease to them.
Assemble: O-rings Thermostat Housing [B] Thermostat [C] Thermostat Cap [D]

Thermostat Installation

Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top.

Tighten: Torque - Thermostat Cap Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
Install the thermostat assembly to the cylinder head.
Tighten: Torque - Thermostat Housing Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Install the removed parts (see appropriate chapters).

Thermostat Installation

Thermostat Removal

Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see T ...

Thermostat Inspection

Remove the thermostat (see Thermostat Removal). Inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. To check valve openi ...

Other materials:

Terminal Numbers of ECU Connectors
1. Subthrottle Valve Actuator: Y/BK 2. Subthrottle Valve Actuator: BK/O 3. Unused 4. Front Wheel Rotation Sensor Signal: G/Y 5. Unused 6. Starter Lockout Switch: R/G 7. Gear Position Switch: G/R 8. Crankshaft Sensor (–): BK 9. Power Supply to Sensors: BL 10. Unused 11. Intake Air Pre ...

Brake Pedal Position Adjustment
NOTE Usually it is not necessary to adjust the pedal position, but always adjust it when push rod locknut has been loosened. Loosen the locknut [A] and turn the push rod with the hex head [B] to achieve the correct pedal position. If the length [C] shown is 69 ±1 mm (2.7 ±0.04 in.), th ...

Specifications
Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNINGWARNING indicates a hazardous situation whi ...