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Kawasaki Ninja H2 Motorcycle Service Manual – PDF
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Kawasaki Ninja H2 Motorcycle Service Manual – PDF DOWNLOAD
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Description
Kawasaki Ninja H2 Motorcycle Service Manual – PDF DOWNLOAD
FILE DETAILS:
Kawasaki Ninja H2 Motorcycle Service Manual – PDF DOWNLOAD
Language : English
Pages : 835
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Kawasaki Ninja H2 Motorcycle Service Manual – PDF DOWNLOAD
General Information 11
Before Servicing 12
Model Identification 17
General Specifications 18
Unit Conversion Table 21
Periodic Maintenance 23
Periodic Maintenance Chart 25
Torque and Locking Agent 28
Specifications 36
Special Tools 38
Periodic Maintenance Procedures 39
Fuel System (DFI) 39
Air Cleaner Element Replacement 39
Idle Speed Inspection 40
Idle Speed Adjustment 40
Throttle Control System Inspection 40
Engine Vacuum Synchronization Inspection 41
Fuel System Inspection 43
Fuel Filter Replacement 43
Fuel Pump Replacement 45
Fuel Hose Replacement 45
Evaporative Emission Control System Inspection (Other than US and CA Models) 47
Cooling System 47
Coolant Level Inspection 47
Cooling System Inspection 48
Coolant Change 48
Water Hose and O-ring Replacement 51
Engine Top End 52
Valve Clearance Inspection 52
Valve Clearance Adjustment 53
Air Suction System Damage Inspection 57
Clutch 57
Clutch System Inspection 57
Clutch Operation Inspection 58
Clutch Fluid Level Inspection 58
Clutch Fluid Change 59
Clutch Hose Replacement 59
Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement 60
Engine Lubrication System 60
Engine Oil Change 61
Oil Filter Replacement 62
Wheels/Tires 62
Air Pressure Inspection 62
Wheels and Tires Inspection 62
Wheel Bearing Damage Inspection 63
Final Drive 64
Drive Chain Lubrication Condition Inspection 64
Drive Chain Slack Inspection 65
Drive Chain Slack Adjustment 65
Drive Chain Wear Inspection 67
Chain Guide Wear Inspection 67
Brakes 68
Brake System Inspection 68
Brake Operation Inspection 69
Brake Fluid Level Inspection 69
Brake Fluid Change 70
Brake Hose and Pipe Replacement 74
Master Cylinder Rubber Parts Replacement 76
Caliper Rubber Parts Replacement 76
Brake Pad Wear Inspection 78
Brake Light Switch Operation Inspection 79
Suspension 80
Suspension System Inspection 80
Lubrication of Rear Suspension 83
Steering 83
Steering Play Inspection 83
Steering Play Adjustment 84
Steering Stem Bearing Lubrication 85
Electronic Steering Damper Oil Leak Inspection 86
Electrical System 87
Lights and Switches Operation Inspection 87
Headlight Aiming Inspection 89
Side Stand Switch Operation Inspection 90
Engine Start/Stop Switch Operation Inspection 91
Spark Plug Condition Inspection 91
Spark Plug Replacement 92
Supercharger 92
Supercharger Oil Screen Replacement 92
Supercharger Impeller Axial Play Inspection 93
Others 95
Chassis Parts Lubrication 95
Condition of Bolts, Nuts and Fasteners Tightness Inspection 96
Fuel System (DFI) 99
Exploded View102
DFI System108
DFI Components Naming110
DFI Parts Location118
Specifications122
Special Tools and Sealants123
DFI Servicing Precautions124
DFI Servicing Precautions124
Troubleshooting the DFI System126
Outline126
Inquiries to Rider130
DFI System Troubleshooting Guide133
Warning Indicator Light (LED)138
Yellow Engine Warning Indicator Light (LED) Inspection138
ECU139
ECU Identification139
ECU Removal139
ECU Installation140
ECU Power Supply Inspection140
DFI Power Source143
ECU Fuse Removal143
ECU Fuse Installation143
ECU Fuse Inspection143
ECU Main Relay Removal/Installation143
ECU Main Relay Inspection143
Fuel Line144
Fuel Pressure Inspection144
Fuel Flow Rate Inspection145
Fuel Pump147
Fuel Pump Removal147
Fuel Pump Installation148
Fuel Pump Operation Inspection148
Fuel Pump Operating Voltage Inspection149
Pressure Regulator Removal150
Fuel Pump Relay Removal/Installation150
Fuel Pump Relay Inspection150
Fuel Injectors151
Primary Fuel Injector Removal/Installation151
Secondary Fuel Injector Removal/Installation151
Primary Fuel Injector Audible Inspection151
Fuel Injector Resistance Inspection151
Fuel Injector Power Source Voltage Inspection151
Fuel Injector Output Voltage Inspection151
Fuel Injector Fuel Line Inspection151
Throttle Grip and Cables152
Free Play Inspection152
Free Play Adjustment152
Cable Installation152
Cable Lubrication152
Air Intake Chamber153
Air Intake Chamber Removal153
Air Intake Chamber Installation155
Blow-off Valve Removal157
Blow-off Valve Installation157
Blow-off Valve Inspection157
Purge Valve (for Supercharger) Removal/Installation157
Purge Valve (for Supercharger) Inspection157
Throttle Body Assy158
Idle Speed Inspection/Adjustment158
Synchronization Inspection158
Throttle Body Assy Removal158
Throttle Body Assy Installation160
Throttle Body Assy Disassembly161
Throttle Body Assy Assembly162
Nozzle Assy164
Nozzle Assy Removal164
Nozzle Assy Installation164
Nozzle Assy Disassembly164
Nozzle Assy Assembly165
Air Cleaner166
Air Cleaner Element Removal/Installation166
Air Cleaner Element Inspection166
Air Cleaner Oil Draining166
Air Cleaner Housing Removal166
Air Cleaner Housing Installation168
Supercharger169
Supercharger Chain Tensioner Removal169
Supercharger Chain Tensioner Installation169
Supercharger Housing Assy Removal170
Supercharger Housing Assy Installation172
Supercharger Outer Housing Removal174
Supercharger Outer Housing Installation174
Fuel Tank176
Fuel Tank Removal176
Fuel Tank Installation178
Fuel Tank and Cap Inspection180
Fuel Tank Cleaning180
Evaporative Emission Control System (Other than US, CA Models)181
Parts Removal/Installation181
Hose Inspection181
Purge Valve Inspection181
Canister Inspection 181
Cooling System183
Exploded View184
Coolant Flow Chart186
Specifications189
Special Tools 190
Coolant191
Coolant Deterioration Inspection191
Coolant Level Inspection191
Coolant Draining191
Coolant Filling191
Pressure Testing191
Cooling System Flushing192
Coolant Reserve Tank Removal/Installation192
Water Pump193
Water Pump Removal193
Water Pump Installation194
Water Pump Inspection195
Water Pump Impeller Disassembly/Assembly195
Water Pump Impeller Inspection195
Water Pump Housing Disassembly196
Water Pump Housing Assembly196
Mechanical Seal Inspection196
Radiator197
Radiator and Radiator Fan Removal197
Radiator and Radiator Fan Installation198
Radiator Inspection200
Radiator Cap Inspection200
Radiator Filler Neck Inspection201
Thermostat202
Thermostat Removal202
Thermostat Installation202
Thermostat Inspection203
Hose and Pipes204
Hose Installation204
Hose Inspection204
Water Temperature Sensor205
Water Temperature Sensor Removal/Installation205
Water Temperature Sensor Inspection205
Engine Top End207
Exploded View208
Exhaust System Identification212
Specifications214
Special Tools and Sealants215
Clean Air System217
Air Suction Valve Removal217
Air Suction Valve Installation217
Air Suction Valve Inspection218
Air Switching Valve Removal218
Air Switching Valve Installation219
Air Switching Valve Operation Test219
Air Switching Valve Unit Test219
Clean Air System Hose Inspection219
Cylinder Head Cover220
Cylinder Head Cover Removal220
Cylinder Head Cover Installation221
Camshaft Chain Tensioner223
Camshaft Chain Tensioner Removal223
Camshaft Chain Tensioner Installation223
Camshaft, Camshaft Chain225
Camshaft Removal225
Camshaft Installation226
Camshaft, Camshaft Cap Wear Inspection229
Camshaft Runout Inspection229
Cam Wear Inspection230
Camshaft Chain Removal230
Camshaft Chain Installation230
Cylinder Head231
Cylinder Compression Measurement231
Cylinder Head Removal232
Cylinder Head Installation232
Cylinder Head Warp Inspection234
Valves235
Valve Clearance Inspection235
Valve Clearance Adjustment235
Valve Removal235
Valve Installation235
Valve Guide Removal235
Valve Guide Installation236
Valve-to-Guide Clearance Measurement (Wobble Method)236
Valve Seat Inspection237
Valve Seat Repair237
Throttle Body Assy Holder242
Throttle Body Assy Holder Removal242
Throttle Body Assy Holder Installation242
Muffler243
Muffler Body Removal243
Muffler Body Installation244
Exhaust Pipe Removal246
Exhaust Pipe Installation249
Exhaust Butterfly Valve Cable Removal250
Exhaust Butterfly Valve Cable Installation251
Exhaust Butterfly Valve Actuator Removal254
Exhaust Butterfly Valve Actuator Installation255
Exhaust Butterfly Valve Actuator Adjustment256
Clutch257
Exploded View258
Specifications260
Special Tools and Sealant261
Clutch Lever262
Clutch Lever Removal/Installation262
Clutch Lever Position Adjustment264
Clutch Master Cylinder265
Clutch Master Cylinder Removal265
Clutch Master Cylinder Installation 265
Clutch Master Cylinder Disassembly/Assembly266
Clutch Master Cylinder Inspection266
Clutch Slave Cylinder267
Clutch Slave Cylinder Removal267
Clutch Slave Cylinder Installation267
Clutch Fluid269
Clutch Fluid Level Inspection269
Clutch Fluid Change269
Bleeding the Clutch Line269
Clutch Hose Removal/Installation271
Clutch Hose Inspection271
Clutch Cover272
Clutch Cover Removal272
Clutch Cover Installation272
Clutch Cover Disassembly272
Clutch Cover Assembly273
Clutch274
Clutch Removal274
Clutch Installation275
Clutch Plate Assembly Length Measurement279
Clutch Plate Assembly Adjustment279
Clutch Plate, Wear, Damage Inspection280
Clutch Plate Warp Inspection280
Clutch Housing Finger Inspection280
Clutch Housing Spline Inspection280
Clutch Pressure Plate and Clutch Hub Inspection281
Clutch Spring Inspection281
Engine Lubrication System283
Exploded View284
Engine Oil Flow Chart286
Specifications288
Special Tools and Sealants289
Engine Oil and Oil Filter290
Oil Level Inspection290
Engine Oil Change290
Oil Filter Replacement290
Oil Pan291
Oil Pan Removal291
Oil Pan Installation291
Oil Screen292
Oil Screen Removal292
Oil Screen Installation292
Oil Screen Cleaning293
Oil Pressure Relief Valve294
Oil Pressure Relief Valve Removal294
Oil Pressure Relief Valve Installation294
Oil Pressure Relief Valve Inspection294
Oil Pump295
Oil Pump Removal295
Oil Pump Installation295
Oil Pump Driven Gear Removal295
Oil Pump Driven Gear Installation296
Oil Pump Driven Gear Shaft Removal296
Oil Pump Driven Gear Shaft Installation297
Oil Cooler298
Oil Cooler Removal298
Oil Cooler Installation298
Oil Pressure Measurement299
Oil Pressure Measurement299
Oil Pressure Switch300
Oil Pressure Switch Removal300
Oil Pressure Switch Installation300
Engine Removal/Installation301
Exploded View302
Engine Removal/Installation304
Engine Removal304
Engine Installation310
Swingarm Mounting Plate Removal312
Swingarm Mounting Plate Installation312
Crankshaft/Transmission313
Exploded View314
Specifications318
Special Tools and Sealants321
Crankcase322
Crankcase Splitting322
Crankcase Assembly323
Crankshaft and Connecting Rods329
Crankshaft Removal329
Crankshaft Installation329
Connecting Rod Removal330
Connecting Rod Installation331
Crankshaft/Connecting Rod Cleaning334
Connecting Rod Bend Inspection334
Connecting Rod Twist Inspection335
Connecting Rod Big End Side Clearance Inspection335
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection335
Crankshaft Side Clearance Inspection337
Crankshaft Runout Inspection337
Crankshaft Main Bearing Insert/Journal Wear Inspection338
Pistons340
Piston Removal340
Piston Installation341
Cylinder (Upper Crankcase) Wear Inspection342
Piston Wear Inspection342
Piston Ring, Piston Ring Groove Wear Inspection342
Piston Ring Groove Width Inspection343
Piston Ring Thickness Inspection343
Piston Ring End Gap Inspection343
Balancer344
Front Balancer Removal344
Front Balancer Installation344
Rear Balancer Removal346
Rear Balancer Installation346
Balancer Adjustment349
Balancer Damper Inspection350
Starter Motor Clutch and Torque Limiter351
Starter Motor Clutch Removal351
Starter Motor Clutch Installation351
Starter Motor Clutch Disassembly351
Starter Motor Clutch Assembly352
Starter Motor Clutch Damper Inspection353
Starter Clutch Inspection353
Torque Limiter Removal353
Torque Limiter Installation353
Transmission354
Transmission Assy Removal354
Transmission Assy Disassembly355
Transmission Assy Assembly356
Transmission Assy Installation357
Transmission Shaft Removal358
Transmission Shaft Installation358
Transmission Shaft Disassembly358
Shift Drum and Fork Removal358
Shift Drum and Fork Installation359
Shift Drum Disassembly/Assembly359
Shift Fork Bending Inspection359
Shift Fork/Shifter Groove Wear Inspection359
Shift Fork Guide Pin/Drum Groove Wear Inspection359
External Shift Mechanism360
Shift Pedal Removal360
Shift Pedal Installation361
External Shift Mechanism Removal363
External Shift Mechanism Installation363
External Shift Mechanism Inspection364
Wheels/Tires367
Exploded View368
Specifications370
Special Tools371
Wheels (Rims)372
Front Wheel Removal372
Front Wheel Installation372
Front Wheel Inspection374
Rear Wheel Removal374
Rear Wheel Installation375
Rear Wheel Inspection375
Axle Inspection376
Balance Inspection377
Balance Adjustment377
Balance Weight Removal378
Balance Weight Installation378
Tires380
Air Pressure Inspection/Adjustment380
Tire Inspection380
Tire Removal380
Tire Installation380
Tire Repair382
Hub Bearing383
Front Hub Bearing Removal383
Front Hub Bearing Installation383
Front Hub Bearing Inspection384
Front Hub Bearing Lubrication384
Final Drive385
Exploded View386
Specifications388
Special Tools389
Drive Chain390
Drive Chain Slack Inspection390
Drive Chain Slack Adjustment390
Drive Chain Wear Inspection390
Drive Chain Lubrication390
Drive Chain Removal390
Drive Chain Installation390
Drive Chain Replacement390
Sprocket, Coupling394
Engine Sprocket Removal394
Engine Sprocket Installation395
Rear Sprocket Removal396
Rear Sprocket Installation396
Coupling Removal397
Coupling Installation397
Coupling Bearing Removal398
Coupling Bearing Installation399
Coupling Bearing Inspection399
Coupling Bearing Lubrication399
Coupling Damper Inspection400
Bearing Housing Removal400
Bearing Housing Installation400
Bearing Housing Bearing Removal401
Bearing Housing Bearing Installation401
Bearing Housing Bearing Inspection402
Sprocket Wear Inspection402
Rear Sprocket Warp Inspection402
Brakes403
Exploded View405
Specifications410
Brake Lever, Brake Pedal411
Brake Lever Removal411
Brake Lever Installation411
Brake Lever Position Adjustment411
Brake Pedal Position Inspection411
Brake Pedal Position Adjustment411
Brake Pedal Removal412
Brake Pedal Installation412
Calipers413
Front Caliper Removal413
Front Caliper Installation413
Rear Caliper Removal414
Rear Caliper Installation415
Brake Pads416
Front Caliper Disassembly416
Front Caliper Assembly416
Caliper Fluid Seal Damage Inspection416
Caliper Piston and Cylinder Damage Inspection416
Front Brake Pad Removal416
Front Brake Pad Installation417
Rear Brake Pad Removal 417
Rear Brake Pad Installation417
Brake Pad Wear Inspection418
Master Cylinder419
Front Master Cylinder Removal419
Front Master Cylinder Installation420
Rear Master Cylinder Removal420
Rear Master Cylinder Installation421
Brake Disc422
Front Brake Disc Removal422
Front Brake Disc Installation422
Rear Brake Disc Removal422
Rear Brake Disc Installation423
Brake Disc Wear Inspection424
Brake Disc Warp Inspection424
Brake Fluid425
Brake Fluid Level Inspection425
Brake Fluid Change425
Brake Line Bleeding425
Brake Hose430
Brake Hose Removal/Installation430
Brake Hose and Pipe Inspection430
Anti-Lock Brake System431
Parts Location431
ABS Servicing Precautions435
ABS Troubleshooting Outline437
Inquiries to Rider440
Self-diagnosis Outline444
ABS and KIBS Indicator Lights (LED) Inspection445
ABS Hydraulic Unit Removal445
ABS Hydraulic Unit Installation446
ABS Hydraulic Unit Inspection447
Front Wheel Rotation Sensor Removal447
Front Wheel Rotation Sensor Installation448
Rear Wheel Rotation Sensor Removal448
Rear Wheel Rotation Sensor Installation449
Wheel Rotation Sensor Inspection450
Wheel Rotation Sensor Air Gap Inspection450
Wheel Rotation Sensor Rotor Inspection451
ABS Solenoid Valve Relay Fuse (15 A) Removal451
ABS Motor Relay Fuse (25 A) Removal451
Fuse Installation451
Fuse Inspection451
Suspension453
Exploded View454
Specifications458
Special Tools459
Front Fork461
Rebound Damping Force Adjustment461
Compression Damping Force Adjustment461
Spring Preload Adjustment462
Front Fork Removal (Each Fork Leg)463
Front Fork Installation (Each Fork Leg)464
Front Fork Oil Change465
Front Fork Disassembly468
Front Fork Assembly469
Inner Tube Inspection470
Dust Seal Inspection471
Spring Tension Inspection471
Rear Shock Absorber472
Rebound Damping Force Adjustment472
Compression Damping Force Adjustment473
Spring Preload Adjustment473
Rear Shock Absorber Removal473
Rear Shock Absorber Installation474
Rear Shock Absorber Inspection474
Rear Shock Absorber Scrapping474
Swingarm475
Swingarm Removal475
Swingarm Installation475
Swingarm Bearing Removal476
Swingarm Bearing Installation477
Swingarm Bearing, Sleeve Inspection477
Swingarm Bearing Lubrication478
Chain Guide Inspection478
Tie-Rod, Rocker Arm479
Tie-Rod Removal479
Tie-Rod Installation479
Rocker Arm Removal480
Rocker Arm Installation481
Tie-Rod and Rocker Arm Bearing Removal482
Tie-Rod and Rocker Arm Bearing Installation482
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection483
Rocker Arm/Tie-Rod Bearing Lubrication483
Steering485
Exploded View486
Special Tools488
Steering489
Steering Inspection489
Steering Adjustment489
Electronic Steering Damper (ESD)490
Electronic Steering Damper Removal490
Electronic Steering Damper Installation490
Electronic Steering Damper Oil Leak Inspection490
Electronic Steering Damper Inspection490
ESD ECU Removal491
ESD ECU Installation491
ESD ECU Inspection491
Steering Stem492
Stem, Stem Bearing Removal492
Stem, Stem Bearing Installation494
Steering Stem Bearing Lubrication496
Steering Stem Warp Inspection497
Stem Cap Deterioration, Damage Inspection497
Handlebar498
Handlebar Removal498
Handlebar Installation499
Frame501
Exploded View502
Seat510
Seat Pad Removal510
Seat Pad Installation510
Seat Pad Disassembly511
Seat Pad Assembly511
Seat Removal512
Seat Installation512
Fairings513
Middle Fairing Removal513
Middle Fairing Installation514
Middle Fairing Disassembly515
Middle Fairing Assembly516
Inner Fairing Removal517
Inner Fairing Installation517
Inner Cover Removal518
Inner Cover Installation518
Upper Fairing Removal519
Upper Fairing Installation520
Upper Fairing Disassembly521
Upper Fairing Assembly522
Lower Fairing Removal525
Lower Fairing Installation526
Intake Duct Removal526
Intake Duct Installation527
Side Covers528
Fuel Tank Cover Removal528
Fuel Tank Cover Installation528
Side Cover Removal528
Side Cover Installation529
Seat Covers530
Hip Support Cover Position Adjustment530
Hip Support Cover Removal530
Hip Support Cover Installation531
Hip Support Cover Disassembly532
Hip Support Cover Assembly532
Seat Cover Removal533
Seat Cover Installation533
Fenders534
Front Fender Removal534
Front Fender Installation534
Flap Removal534
Flap Installation535
Flap Disassembly535
Flap Assembly536
Rear Fender Removal537
Rear Fender Installation540
Frame541
Frame Inspection541
Rear Frame Rear Removal541
Rear Frame Rear Installation541
Rear Frame Front Removal542
Rear Frame Front Installation542
Windshield543
Windshield Removal543
Windshield Installation543
Guard544
Mud Guard Removal544
Mud Guard Installation544
Side Stand545
Side Stand Removal545
Side Stand Installation546
Rear View Mirrors547
Rear View Mirror Removal547
Rear View Mirror Installation547
Electrical System549
Exploded View552
Specifications558
Special Tools and Sealant559
Parts Location560
Wiring Diagram (US, CAL and CA Models)564
Wiring Diagram (Other than US, CAL and CA Models)566
Precautions568
Electrical Wiring569
Wiring Inspection569
Battery570
Battery Removal570
Battery Installation570
Precautions570
Interchange571
Charging Condition Inspection571
Refreshing Charge572
Charging System573
Alternator Cover Removal573
Alternator Cover Installation573
Stator Coil Removal574
Stator Coil Installation574
Alternator Rotor Removal574
Alternator Rotor Installation575
Charging Voltage Inspection576
Alternator Inspection576
Regulator/Rectifier Removal578
Regulator/Rectifier Installation578
Regulator/Rectifier Inspection579
Ignition System582
Crankshaft Sensor Removal582
Crankshaft Sensor Installation582
Crankshaft Sensor Inspection583
Crankshaft Sensor Peak Voltage Inspection583
Camshaft Position Sensor Removal584
Camshaft Position Sensor Installation584
Camshaft Position Sensor Inspection584
Camshaft Position Sensor Peak Voltage Inspection585
Timing Rotor Removal585
Timing Rotor Installation585
Stick Coil Removal586
Stick Coil Installation586
Stick Coil Inspection586
Stick Coil Primary Peak Voltage Inspection586
Spark Plug Removal587
Spark Plug Installation587
Spark Plug Condition Inspection587
Interlock Operation Inspection588
IC Igniter Inspection589
Electric Starter System592
Starter Motor Removal592
Starter Motor Installation592
Starter Motor Disassembly593
Starter Motor Assembly593
Brush Inspection595
Commutator Cleaning and Inspection595
Armature Inspection596
Brush Lead Inspection596
Left-hand End Cover Inspection596
Starter Relay Inspection596
Lighting System599
Headlight Beam Horizontal Adjustment599
Headlight Beam Vertical Adjustment599
Headlight (LED) Assembly Removal/Installation599
Headlight (LED) Assembly Disassembly599
Headlight (LED) Assembly Assembly599
City Light (LED) Removal/Installation599
Tail/Brake Light (LED) Removal600
Tail/Brake Light (LED) Installation600
License Plate Light Bulb Replacement601
Turn Signal Light (LED) Replacement602
Air Switching Valve604
Air Switching Valve Operation Test604
Air Switching Valve Unit Test604
Radiator Fan System606
Fan Motor Inspection606
Meter, Gauge, Indicator Unit608
Meter Unit Removal608
Meter Unit Installation608
Meter Operation Inspection609
Meter Operation Inspection611
Meter Unit Inspection612
Immobilizer System (Equipped Models)618
Operational Cautions618
Key Registration618
Immobilizer System Parts Replacement636
Immobilizer System Inspection638
Switches and Sensors640
Brake Light Timing Inspection640
Brake Light Timing Adjustment640
Switch Inspection640
Water Temperature Sensor Inspection641
Oxygen Sensor Removal641
Oxygen Sensor Installation642
Oxygen Sensor Inspection642
Fuel Reserve Switch Inspection642
Gear Position Sensor Removal643
Gear Position Sensor Installation643
Gear Position Sensor Inspection643
Relay Box644
Relay Box Removal644
Relay Circuit Inspection644
Diode Circuit Inspection645
Fuse647
30 A Main/15 A ECU Fuse Removal647
Fuse Box Fuse Removal647
Fuse Installation648
Fuse Inspection648
Self-Diagnosis System649
Specifications653
Special Tools655
Self-Diagnosis656
Self-Diagnosis Outline656
Self-Diagnosis Procedures657
Service Code Reading660
Service Code Erasing660
Backups663
Throttle Position Sensor (Service Code 11) (DTC P0120, P0121, P0122, P0220, P0223)671
Throttle Position Sensor Removal671
Throttle Position Sensor Input Voltage Inspection671
Throttle Position Sensor Output Voltage Inspection672
Intake Air Pressure Sensor (Service Code 12) (DTC P0105, P0107)674
Intake Air Pressure Sensor Removal674
Intake Air Pressure Sensor Installation674
Intake Air Pressure Sensor Input Voltage Inspection675
Intake Air Pressure Sensor Output Voltage Inspection676
Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112)680
Air Intake Chamber Pressure/Temperature Sensor Removal680
Air Intake Chamber Pressure/Temperature Sensor Installation680
Intake Air Temperature Sensor Output Voltage Inspection681
Intake Air Temperature Sensor Resistance Inspection682
Water Temperature Sensor (Service Code 14) (DTC P0115, P0117)683
Water Temperature Sensor Removal/Installation683
Water Temperature Sensor Output Voltage Inspection684
Water Temperature Sensor Resistance Inspection685
Atmospheric Pressure Sensor (Service Code 15) (DTC P2226, P2228)686
Atmospheric Pressure Sensor Removal686
Atmospheric Pressure Sensor Installation686
Atmospheric Pressure Sensor Input Voltage Inspection687
Atmospheric Pressure Sensor Output Voltage Inspection688
Accelerator Position Sensor (Service Code 18) (DTC P2120, P2121, P2123, P2125, P2128)692
Accelerator Position Sensor Removal692
Accelerator Position Sensor Input Voltage Inspection692
Accelerator Position Sensor Output Voltage Inspection693
Accelerator Position Sensor Resistance Inspection694
ABS Hydraulic Unit Communication Error (Service Code 1B)696
ABS Hydraulic Unit Communication Line Inspection696
Crankshaft Sensor (Service Code 21) (DTC P0335)698
Crankshaft Sensor Removal/Installation698
Crankshaft Sensor Resistance Inspection698
Crankshaft Sensor Peak Voltage Inspection698
Camshaft Position Sensor (Service Code 23) (DTC P0340)699
Camshaft Position Sensor Removal/Installation699
Camshaft Position Sensor Resistance Inspection699
Camshaft Position Sensor Peak Voltage Inspection699
Rear Wheel Rotation Sensor Signal (Service Code 24) (DTC P2158)701
Rear Wheel Rotation Sensor Signal Inspection701
Gear Position Sensor (Service Code 25) (DTC P0914, P0917)703
Gear Position Sensor Removal/Installation703
Gear Position Sensor Input Voltage Inspection703
Gear Position Sensor Output Voltage Inspection704
Front Wheel Rotation Sensor Signal (Service Code 27) (DTC P0500)706
Front Wheel Rotation Sensor Signal Inspection706
Vehicle-down Sensor (Service Code 31) (DTC C0064)708
Vehicle-down Sensor Removal708
Vehicle-down Sensor Installation708
Vehicle-down Sensor Input Voltage Inspection709
Vehicle-down Sensor Output Voltage Inspection710
Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132)713
Oxygen Sensor Removal/Installation713
Oxygen Sensor Inspection713
Exhaust Butterfly Valve Actuator Sensor (Service Code 34) (DTC P048B, P048E)716
Exhaust Butterfly Valve Actuator Sensor Removal/Installation716
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection716
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection717
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection718
Immobilizer Amplifier (Service Code 35, Equipped Models)719
Antenna Resistance Inspection719
Amplifier Input Voltage Inspection719
Blank Key Detection (Service Code 36, Equipped Models)720
Ignition Key Inspection720
ECU Communication Error (Service Code 39) (DTC U0001)721
ECU Communication Line Inspection721
Purge Valve (Service Code 3A, Other than US and CA Models) (DTC P0443)723
Purge Valve Removal/Installation723
Purge Valve Inspection723
ESD ECU Communication Error (Service Code 3C)725
ESD ECU Communication Line Inspection725
Quick Shifter Sensor (Service Code 3E) (DTC P0826)727
Quick Shifter Sensor Removal/Installation727
Quick Shifter Sensor Input Voltage Inspection727
Quick Shifter Sensor Output Voltage Inspection728
Quick Shifter Sensor Resistance Inspection729
Primary Fuel Injectors #1, #2, #3, #4 (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204)730
Primary Fuel Injector Removal/Installation730
Primary Fuel Injector Audible Inspection730
Primary Fuel Injector Resistance Inspection730
Primary Fuel Injector Power Source Voltage Inspection731
Primary Fuel Injector Output Voltage Inspection732
Primary Fuel Injector Fuel Line Inspection734
Fuel Pump Relay (Service Code 46) (DTC P0627)736
Fuel Pump Relay Removal/Installation736
Fuel Pump Relay Inspection736
Return Spring (Service Code 49) (DTC P2119)737
Return Spring Removal737
Return Spring Inspection737
Secondary Fuel Injectors #1, #2, #3, #4 (Service Code 4A, 4B, 4C, 4D) (DTC P0205, P0206, P0207, P0208)738
Secondary Fuel Injector Removal/Installation738
Secondary Fuel Injector Resistance Inspection738
Secondary Fuel Injector Power Source Voltage Inspection739
Secondary Fuel Injector Output Voltage Inspection740
Secondary Fuel Injector Fuel Line Inspection741
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354)743
Stick Coil Removal/Installation743
Stick Coil Primary Winding Resistance Inspection743
Stick Coil Input Voltage Inspection743
Radiator Fan Relay (Service Code 56) (DTC P0480)745
Radiator Fan Relay Removal/Installation745
Radiator Fan Relay Inspection745
ETV Actuator (Service Code 58) (DTC P2100)747
ETV Actuator Removal747
ETV Actuator Input Voltage Inspection747
ETV Actuator Relay Inspection747
Exhaust Butterfly Valve Actuator (Service Code 63) (DTC P0475)749
Exhaust Butterfly Valve Actuator Removal749
Exhaust Butterfly Valve Actuator Installation749
Exhaust Butterfly Valve Actuator Inspection749
Exhaust Butterfly Valve Actuator Resistance Inspection749
Air Switching Valve (Service Code 64) (DTC P0410)751
Air Switching Valve Removal/Installation751
Air Switching Valve Inspection751
Oxygen Sensor Heater (Service Code 67) (DTC P0030)752
Oxygen Sensor Heater Removal/Installation752
Oxygen Sensor Heater Resistance Inspection752
Oxygen Sensor Heater Power Source Voltage Inspection753
Knock Sensor (Service Code 69) (DTC P0325)755
Knock Sensor Removal755
Knock Sensor Installation755
Knock Sensor Resistance Inspection755
Purge Valve (for Supercharger) (Service Code 6A) (DTC P0045)757
Purge Valve (for Supercharger) Removal/Installation757
Purge Valve (for Supercharger) Inspection757
Air Intake Chamber Pressure Sensor (Service Code 7E) (DTC P0235, P0237)759
Air Intake Chamber Pressure/Temperature Sensor Removal759
Air Intake Chamber Pressure/Temperature Sensor Installation759
Air Intake Chamber Pressure Sensor Input Voltage Inspection760
Air Intake Chamber Pressure Sensor Output Voltage Inspection761
Fuel Supply System (Service Code 94) (DTC P0170)763
Fuel Supply System Inspection763
Battery Voltage (Service Code 97) (DTC P0562)764
Battery Voltage Inspection764
ETV Control Circuit (Service Code 98) (DTC P0607)765
ETV Control Circuit Inspection765
ESD Actuator Error (Service Code E2E)766
ESD Actuator Removal766
ESD Actuator Installation766
ESD Actuator Resistance Inspection766
ESD Actuator Input Voltage Inspection767
ESD ECU Error (Service Code E3B)769
ESD ECU Removal769
ESD ECU Installation769
ESD ECU Power Supply Inspection769
ESD Calibration Error (Service Code E3F)772
IMU (Inertial Measurement Unit) (Service Code E8E)773
IMU Removal773
IMU Installation773
IMU Power Supply Inspection773
IMU (Inertial Measurement Unit) Communication Error (Service Code E8F)775
IMU Communication Line Inspection775
ABS Service Codes777
Solenoid Valve Inspection (Service Code B13, B14, B17, B18)777
ABS Solenoid Valve Relay Inspection (Service Code B19)777
Front, Rear Wheel Rotation Difference Abnormal Inspection (Service Code B25)777
ABS Motor Relay Inspection (Service Code B35)777
Front Wheel Rotation Sensor Signal Abnormal (Service Code B42)778
Front Wheel Rotation Sensor Wiring Inspection (Service Code B43)779
Rear Wheel Rotation Sensor Signal Abnormal (Service Code B44)779
Rear Wheel Rotation Sensor Wiring Inspection (Service Code B45)780
Power Supply Voltage Inspection (Low-Voltage) (Service Code B52)781
Power Supply Voltage Inspection (Over-Voltage) (Service Code B53)781
ECU Inspection (Service Code B55)781
CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code B57) CAN Communication (Reception) Monitor Inspection (Service Code B58)781
ECU Communication Line Inspection (Service Code B62)782
IMU Communication Line Inspection (Service Code B63)783
Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code B83)783
Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code B84)783
Fluid Pressure Sensor Supply Voltage Inspection (Service Code B89)784
IMU Inspection (Service Code B94)784
Appendix785
Cable, Wire, and Hose Routing786
Troubleshooting Guide828
DESCRIPTION:
Kawasaki Ninja H2 Motorcycle Service Manual – PDF DOWNLOAD
FOREWORD:
- This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work.
- A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
- In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment.
- Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this servicemanual.
- Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle.
- Follow the Periodic Maintenance Chart in the Service Manual.
How to Use This Manual:
- In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive
- Table of Contents. For example, if you want stick coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Stick Coil section. Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices.
•Be alert for problems and non-scheduled maintenance.
•Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
•Follow the procedures in this manual carefully. Don’t take shortcuts.
•Remember to keep complete records ofmaintenance and repair with dates and any new parts installed.
G.B 04/04/25
