Kawasaki Ninja Service Manual: Fuel Tank Removal

Kawasaki Ninja Service Manual / Fuel System (DFI) / Fuel Tank / Fuel Tank Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.

Disconnect the battery (–) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

Turn the ignition switch to OFF.
Wait until the engine cools down.
Remove: Front Seat (see Front Seat Removal in the Frame chapter)
Open the fuel tank cap [A] to lower the pressure in the tank.

During tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less.

Fuel Tank Removal

Draw the fuel out from the fuel tank with a commercially available pump [A].

Use a soft plastic hose [B] as a pump intake hose in order to insert the hose smoothly.

Put the hose through the fill opening [C] into the tank and draw the fuel out.

Front [D]

Fuel Tank Removal

WARNING

Spilled fuel is flammable and can be explosive under certain conditions. The fuel can not be removed completely from the fuel tank. Be careful for remained fuel spillage.

Remove: Bolts [A] Fuel Tank Covers (Both Sides) [B]

Clear the hook fastener [C], projections [D] and hook portion [E].

Fuel Tank Removal

Remove the relay box [A] from the left fuel tank cover [B].

Fuel Tank Removal

Remove: Bolts (Both Sides) [A] Upper Fuel Tank Cover [B]

Clear the projections [C] from the holes.

Fuel Tank Removal

Remove: Fuel Tank Bolts (Both Sides) [A] Fuel Tank Bracket Bolts [B]

Fuel Tank Removal

Lift up the front portion of the fuel tank, and then disconnect the hoses [A].
For the California and Southeast Asia models, disconnect the following.

Fuel Return Hose

Fuel Tank Removal

Disconnect: Battery (–) Terminal Fuel Pump Lead Connector [A]

Fuel Tank Removal

Be sure to place a piece of cloth around the fuel hose joint.
Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush.

Fuel Tank Removal

When removing with standard tip screwdriver

Insert the standard tip screwdriver [A] into the slit on the joint lock [B].
Turn the driver to disconnect the joint lock.

When removing with fingers

Open and push up [C] the joint lock with your 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.

Pull the fuel hose out of the pipe.
Cover the delivery pipe with the vinyl bag to keep it clean.

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.

Close the fuel tank cap.
Remove the fuel tank, and place a it on a flat surface.

Do not apply the load to the fuel outlet pipe of the fuel pump.

For the California and Southeast Asia models, note the following.

NOTICE

For the California and Southeast Asia models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.

Be sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal.

WARNING

Spilled fuel is flammable and can be explosive under certain conditions. For California and Southeast Asia models, be careful not to spill fuel through the return hose.

If liquid or gasoline flows into the breather hose, remove the hose and blow it clean with compressed air.

Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump.

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Store the fuel tank in an area which is well-ventilated and free from any source of flame or sparks. Do not smoke in this area. Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage.

Fuel Tank

...

Fuel Tank Installation

Note the above WARNING (see Fuel Tank Removal). Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Check that the dampers [A] are in place on the fue ...

Other materials:

Brake Hose and Pipe Replacement
NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Brake Hose Fitting Bolt [A] Brake Hose Banjo Bolts [B] Bolt [C] Clamp ...

Brakes
Brake Wear Inspection Inspect the brakes for wear. For each front and rear disc brake caliper, if the thickness of either pad is less than 1 mm (0.04 in.), replace both pads in the caliper as a set. Pad replacement should be done by an authorized Kawasaki dealer. A. Lining Thickness B. ...

ESD Actuator Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Disconnect the ESD actuator connector and connect a suitable measuring leads [A] between these connectors as shown. Main Harness [B] ESD Actuator [C] Connect the peak voltage adapter [D] and a digital ...