Kawasaki Ninja Service Manual: Fuel Hose Replacement

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Replacement Parts / Fuel Hose Replacement

WARNING

Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage.

For Primary Fuel Hose (Fuel Tank Throttle Body Assy)


For Primary Fuel Hose (Fuel Tank  Throttle Body Assy)


When removing with standard tip screwdriver

When removing with fingers

When removing with fingers


NOTICE

Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing.

When removing with fingers


The fuel hose in Brazil model has yellow paint [B].

When removing with fingers


Check the yellow paint of the fuel hose in the throttle body assy side (Brazil model only).

When removing with fingers


When removing with fingers


WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

For Secondary Fuel Hose (Throttle Body Assy Nozzle Assy)


For Secondary Fuel Hose (Throttle Body Assy  Nozzle Assy)


When removing with standard tip screwdriver

When removing with fingers

When removing with fingers


NOTICE

Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing.

When removing with fingers


The fuel hose in Brazil model has yellow paint [B].

When removing with fingers


Check the yellow paint of the fuel hose in the throttle body assy side (Brazil model only).

When removing with fingers


WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

When removing with fingers


When removing with fingers


NOTICE

When inserting the fuel hose joint, do not apply strong force to the delivery pipe [E] on the nozzle assy. The pipe made from resin could be damaged.

NOTICE

When pushing and pulling the fuel hose joint, do not apply strong force to the delivery pipe [C] on the nozzle assy. The pipe made from resin could be damaged.

Fuel Hose Replacement


WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint.

Air Cleaner Element Replacement
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Coolant Change
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 ...

Other materials:

Intake Air Pressure Sensor #2 Removal
NOTICE Never drop the intake air pressure sensor #2 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 #2 Connector [A] Remove the intake air ...

Valve Removal
Remove the cylinder head (see Cylinder Head Removal). Remove the valve lifter and shim. Mark and record the valve lifter and shim locations so they can be installed in their original positions. Using the valve spring compressor assembly, remove the valve. Special Tools - Valve ...

Transmission Assy Assembly
Install the ball bearing [A] until it is bottomed. Turn the oil seal side to the bottom. Special Tool - Bearing Driver Set: 57001-1129 Install the bearing holder [B]. Turn the flat side to the bottom. Apply a non-permanent locking agent to the bearing holder bolts [C]. Tighten: ...