Kawasaki Ninja 300 / Ninja 300 ABS Motorcycle. Service Manual (2013)

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Idle Speed Inspection

•

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebars to both sides
[A].
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed or damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection and Cable, Wire, and Hose Routing section in
the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding Condition. Follow the service manual to be
make sure to correct any of these conditions.

•

Check the idle speed.

Idle Speed

Standard:

1 300 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it.

Idle Speed Adjustment

•

Start the engine and warm it up thoroughly.

•

Turn the adjusting screw [A] until the idle speed is correct.

○

Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.

Throttle Control System Inspection

•

Check that the throttle grip [A] moves smoothly from full
open to close, and the throttle closes quickly and com-
pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throt-
tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.

•

Check the throttle grip free play [B].

Throttle Grip Free Play

Standard:

∼

3 mm (0.08

∼

0.12 in.)

•

Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increases, check the throttle cable free
play and the cable routing.
If necessary, adjust the throttle cable as follows.

•

Loosen the locknut [A].

•

Turn the adjuster [B] until the proper amount of free play
can be obtained.

•

Tighten the locknut against the adjuster securely.

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

If the throttle grip free play can not be adjusted with the
adjuster, use the adjusters in the lower ends of the throttle
cables.

•

Remove:

Left Middle Fairing (see Middle Fairing Removal in the
Frame chapter)

•

Turn out both upper nuts [A] and turn in both lower nuts [B]
as far as they will go so as to give the throttle grip plenty
of play.

•

With the throttle grip completely closed, turn out the lower
nut and turn in the upper nut of the decelerator cable [C]
until the inner cable just becomes tight.

•

Turn out the lower nut and turn in the upper nut of the
accelerator cable [D] until the correct free play is obtained.

•

Check that the throttle linkage lever [A] stops against the
adjusting screw [B] with the throttle grip closed.

Engine Vacuum Synchronization Inspection

NOTE

○

These procedures are explained on the assumption that
the intake and exhaust systems of the engine are in
good condition.

•

Situate the motorcycle so that it is vertical.

•

Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).

•

Remove the rubber caps [A] from the fittings of each throt-
tle body.

•

Disconnect the air switching valve hose [A] from the air
cleaner housing.

•

Plug the air switching valve hose end and air cleaner
housing fitting.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Connect a vacuum gauge (special tool) and hoses [A] to
the fittings on the throttle body.

Special Tool - Vacuum Gauge: 57001-1369

•

Connect a highly accurate tachometer to one of the stick
coil primary leads.

•

Remove the fuel hose (see Fuel Tank Removal in the Fuel
System (DFI) chapter).

•

Connect the following parts temporary.

Fuel Pump Lead Connector [A]
Extension Tube [B]

Special Tool - Extension Tube: 57001-1578

•

Start the engine and warm it up thoroughly.

•

Check the idle speed, using a highly accurate tachometer.

Idle Speed

Standard: 1 300 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it with
the adjusting screw (see Idle Speed Adjustment).

NOTICE

Do not measure the idle speed by the tachometer of
the meter unit.

•

While idling the engine, inspect the throttle body vacuum,
using the vacuum gauge [A].

Throttle Body Vacuum

Standard: 24.7 ±1.33 kPa (185 ±10 mmHg) at idle speed

If any one vacuum is not within the specification, turn in
the bypass screws until it seats fully but not tightly.

NOTICE

Do not over tighten them. They could be damaged,
requiring replacement.

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

•

Turn out the bypass screw of the higher vacuum between
#1 [A] and #2 [B] to the lower vacuum.

•

Open and close the throttle valves after each measure-
ment and adjust the idle speed as necessary.

•

Inspect the vacuums as before.
If both vacuums are within the specification, finish the en-
gine vacuum synchronization.
If any vacuum can not be adjusted within the specification,
remove the bypass screws #1, #2 and clean them.

•

Remove:

Bypass Screw [A]
Spring [B]
Washer [C]
O-ring [D]

•

Check the bypass screw and its hole for carbon deposits.
If any carbons accumulate, wipe the carbons off from the
bypass screw and the hole, using a cotton pad penetrated
with a high flash-point solvent.

•

Replace the O-ring with a new one.

•

Check the tapered portion [E] of the bypass screw for
wear or damage.
If the bypass screw is worn or damaged, replace it.

•

Turn in the bypass screw until it seats fully but not tightly.

•

Repeat the same procedure for other bypass screw.

•

Repeat the synchronization.
If the vacuums are correct, check the output voltage of
the main throttle sensor (see Main Throttle Sensor Output
Voltage Inspection in the Fuel System (DFI) chapter).

Special Tool - Throttle Sensor Setting Adapter:

57001

-1538

Main Throttle Sensor Output Voltage

Connections to Adapter:

Digital Meter (+)

→

R (sensor Y/W) lead

Digital Meter (–)

→

W (sensor BR/BK) lead

Standard: DC 1.020

∼

1.050 V at idle throttle opening

If the output voltage is out of the standard, check the in-
put voltage of the main throttle sensor (see Main Throttle
Sensor Input Voltage Inspection in the Fuel System (DFI)
chapter).

•

Remove the vacuum gauge hoses and install the rubber
caps on the original position.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System

Fuel Hose Inspection (fuel leak, damage, installation
condition)

○

If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Re-
moval in the Fuel System (DFI) chapter) and check the
fuel hose.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.

•

Check that the hose is routed according to Cable, Wire,
and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.

Hose Joints [A]
Fuel Hose [B]

•

Check that the hose joints are securely connected.

○

Push and pull [A] the hose joint [B] back and forth more
than two times, and make sure it is locked and does not
come off.

Fuel Pump Side [C]
Throttle Body Assy Side [D]

WARNING

Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is in-
stalled correctly on the delivery pipe by sliding the
joint.

If it comes off, reinstall the hose joint.

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

Fuel Hose Replacement

WARNING

Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.

NOTICE

When removing and installing the fuel hose joint, do
not apply strong force to the outlet pipe on the fuel
pump and delivery pipe on the throttle body assy.
The pipes made from resin could be damaged.

•

Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).

•

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.

When removing with standard tip screwdriver

•

Insert the standard tip screwdriver [A] into 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.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Pull the fuel hose joint [A] out of the delivery pipe.

•

Clean the delivery pipe.

•

Cover the delivery pipe with the vinyl bag to keep it clean.

•

Remove the vinyl bag on the pipe.

•

Check that there are no flaws, burrs, and adhesion of
foreign materials on the delivery pipe [A].

•

Replace the fuel hose with a new one.

•

Install the fuel hose so that the white mark side faces
delivery pipe of the fuel pump.

•

Insert the fuel hose joint [A] straight onto the delivery pipe
until the hose joint clicks.

•

Push the joint lock [B] until the hose joint clicks.

•

Push and pull [A] the fuel hose joint [B] back and forth
more than two times, and make sure it is locked and does
not come off.

WARNING

Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is in-
stalled correctly on the delivery pipe by sliding the
joint.

If it comes off, reinstall the hose joint.

•

Run the fuel hose correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).

•

Install the fuel tank (see Fuel Tank Installation in the Fuel
System (DFI) chapter).

•

Start the engine and check the fuel hose for leaks.

PERIODIC MAINTENANCE 2-23

Periodic Maintenance Procedures

Evaporative Emission Control System Inspection

(CAL Model)

•

Inspect the canister as follows.

○

Remove:

Left Middle Fairing (see Middle Fairing Removal in the
Frame chapter)

○

Remove the canister [A], and disconnect the hoses from
the canister.

○

Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.

NOTE

○

The canister is designed to work well through the motor-
cycle’s life without any maintenance if it is used under
normal conditions.

•

Inspect the purge valve [B] (see Purge Valve Inspection
in the Fuel System (DFI) chapter).

○

Check that the hoses are securely connected and clips
are in position.

○

Replace any kinked, deteriorated or damaged hoses.

○

Run the hoses according to Cable, Wire, and Hose Rout-
ing section in the Appendix chapter.

○

When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and run the hoses with a minimum of
bending so that the emission flow will not be obstructed.

Cooling System

Coolant Level Inspection

NOTE

○

Check the level when the engine is cold (room or ambi-
ent temperature).

•

Check the coolant level in the reserve tank [A] with the
motorcycle held perpendicular (Do not use the side-
stand.).
If the coolant level is lower than the “L” level line [B], un-
screw the reserve tank cap and add coolant to the “F”
level line [C].

“L”: low
“F”: full

NOTICE

For refilling, add the specified mixture of coolant
and soft water.

Adding water alone dilutes the

coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reserve tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Cooling System

Water Hose and Pipe Inspection (coolant leak, damage,
installation condition)

○

The high pressure inside the radiator hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained.

•

Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard and
brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.

•

Check that the hoses are securely connected and clamps
are tightened correctly.

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,

27 in·lb)

Coolant Change

WARNING

Coolant 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; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.

•

Remove the middle fairings (see Middle Fairing Removal
in the Frame chapter).

•

Remove the radiator cap [A] in two steps. First turn the
cap counterclockwise to the first stop. Then push and turn
it further in the same direction and remove the cap.

PERIODIC MAINTENANCE 2-25

Periodic Maintenance Procedures

•

Place a container under the coolant drain bolts [A], then
remove the drain bolts.

○

The coolant will drain from the radiator and engine.

•

Remove the hose [A].

•

Pour the coolant into a suitable container.

•

Install the hose.

•

Tighten the drain bolts with the gasket.

○

Replace the drain bolt gaskets with new ones.

Torque - Coolant Drain Bolt (Water Pump): 9.8 N·m (1.0

kgf·m, 87 in·lb)

Coolant Drain Bolt (Cylinder): 5.9 N·m (0.60 kgf·m,

52 in·lb)

•

When filling the coolant, choose a suitable mixture ratio
by referring to the coolant manufacturer’s directions.

NOTICE

Soft or distilled water must be used with the an-
tifreeze in the cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and consider-
ably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio (Recommended)

Soft Water:

50%

Coolant:

50%

Freezing Point:

–35°C (–31°F)

Total Amount:

1.5 L (1.6 US qt)

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Fill the radiator up to the filler neck [A] with coolant.

NOTE

○

Pour in the coolant slowly so that it can expel the air
from the engine and radiator.

•

Check the cooling system for leaks.

•

Tap the radiator hoses to force any air bubbles caught
inside.

•

Fill the radiator up to the filler neck with coolant.

•

Fill the reserve tank up to the “F” (full) level line [A] with
coolant and install the cap [B].

•

Install the radiator cap.

•

Start the engine, warm it up thoroughly until the radiator
fan turns on and then stop the engine.

•

Check the coolant level in the reserve tank after the en-
gine cools down.
If the coolant level is lower than the “L” (low) level line [C],
add coolant to the “F” level line.

NOTICE

Do not add more coolant above the “F” level line.

Water Hose and O-ring Replacement

•

Drain the coolant (see Coolant Change).

•

Remove:

Thermostat Housing [A] (see Thermostat Housing Re-
moval in the Cooling System chapter)
Water Pump Cover [B] (see Water Pump Cover Removal
in the Cooling System chapter)
O-rings [C]
Hoses [D]

•

Apply grease to the new O-rings and install them.

•

Install the new hoses and tighten the clamps securely.

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,

27 in·lb)

•

Fill the coolant (see Coolant Change).

•

Check the cooling system for leaks.

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

Engine Top End

Valve Clearance Inspection

NOTE

○

Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).

•

Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-
moval in the Engine Top End chapter)
Plugs [A] [B]

Special Tool - Filler Cap Driver: 57001-1454

•

Check the valve clearance when the pistons are at TDC.

○

The pistons are numbered beginning with the engine left
side.

•

Using a wrench on the alternator rotor bolt, turn the crank-
shaft counterclockwise until the “2T” mark [A] on the al-
ternator rotor is aligned with the projection [B] in the in-
spection window on the alternator cover.

○

Measure the valve clearance of the valves for which the
cam [A] are turned away from each other.

•

Using the thickness gauge [A], measure the valve clear-
ance between the cam and the valve lifter.

Valve Clearance

Standard:

Exhaust 0.22

∼

0.29 mm (0.0087

∼

0.0114 in.)

Intake

0.15

∼

0.24 mm (0.0059

∼

0.0094 in.)

○

Each piston has two intake and two exhaust valves.
Measure these two intake or exhaust valves at the same
crankshaft position.

Valve Clearance Measuring Position

#1 Piston TDC at End of Compression Stroke:

Intake Valve Clearances of #1 Piston
Exhaust Valve Clearances of #1 Piston

NOTE

○

Check the valve clearance using this method only.
Checking the clearance at any other cam position may
result in improper valve clearance.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Valve Clearance Measuring Position

#2 Piston TDC at End of Compression Stroke:

Intake Valve Clearances of #2 Piston
Exhaust Valve Clearances of #2 Piston

If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.

Valve Clearance Adjustment

•

To change the valve clearance, remove the camshaft
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.

NOTE

○

Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.

•

Clean the shim to remove any dust or oil.

•

Measure the thickness of the removed shim [A].

•

Select a new shim thickness calculation as follows.

a + b – c = d
[a] Present Shim Thickness
[b] Measured Valve Clearance
[c] Specified Valve Clearance (Mean Value = 0.26 mm
(Exhaust), 0.20 mm (Intake))
[d] Replace Shim Thickness

Example (Intake):

2.90 + 0.45 – 0.20 = 3.15 mm

○

Exchange the shim for the 3.15 size shim.

PERIODIC MAINTENANCE 2-29

Periodic Maintenance Procedures

Adjustment Shims

Thickness

Part Number

Mark

2.50

92180-1014

2.55

92180-1016

2.60

92180-1018

2.65

92180-1020

2.70

92180-1022

2.75

92180-1024

2.80

92180-1026

2.85

92180-1028

2.90

92180-1030

2.95

92180-1032

3.00

92180-1034

3.05

92180-1036

3.10

92180-1038

3.15

92180-1040

3.20

92180-1042

3.25

92180-1044

3.30

92180-1046

3.35

92180-1048

3.40

92180-1050

3.45

92180-1052

3.50

92180-1054

NOTICE

Be sure to remeasure the clearance after selecting a
shim. If the clearance is out of the specified range,
use the additional shim.

○

If there is no valve clearance, use a shim that is a few
sizes smaller, and remeasure the valve clearance.

•

When installing the shim, face the marked side toward
the valve lifter. At this time, apply engine oil to the shim
to keep the shim in place during camshaft installation.

NOTICE

Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing ex-
tensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.

•

Apply molybdenum disulfide oil solution to the valve lifter
surface and install the lifter.

•

Install the camshaft (see Camshaft Installation in the En-
gine Top End chapter).

•

Recheck the valve clearance and readjust if necessary.

•

Install the removed parts (see appropriate chapters).

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Air Suction System Damage Inspection

•

Remove:

Middle Fairings (see Middle Fairing Removal in the
Frame chapter)
Fuel Tank Bolts (see Fuel Tank Removal in the Fuel Sys-
tem (DFI) chapter)

•

Remove the air switching valve hose [A] from the air
cleaner housing.

•

Start the engine and run it at idle speed.

•

Plug the air switching valve hose end with your finger and
feel vacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve
(see Air Switching Valve Unit Test in the Electrical Sys-
tem chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).

Clutch

Clutch Operation Inspection

•

Pull the clutch lever just enough to take up the free play
[A].

•

Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.

Clutch Lever Free Play

Standard:

∼

3 mm (0.08

∼

0.12 in.)

WARNING

The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.

•

Turn the adjuster [A] so that 5

∼

6 mm (0.20

∼

0.24 in.) [B]

of threads are visible.

PERIODIC MAINTENANCE 2-31

Periodic Maintenance Procedures

•

Slide the dust cover [A] at the clutch cable lower end out
of place.

•

Loosen both adjusting nuts [B] at the clutch cover as far
as they will go.

•

Pull the clutch outer cable [C] tight and tighten the adjust-
ing nuts against the cable holder [D].

•

Slip the dust cover back onto place.

•

Turn the adjuster at the clutch lever until the free play is
correct.

WARNING

Too much cable play can prevent clutch disengage-
ment and cause an accident resulting in serious in-
jury or death. When adjusting the clutch or replac-
ing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.

•

After the adjustment, start the engine and check that the
clutch does not slip and that it releases properly.

Engine Lubrication System

Engine Oil Change

•

Situate the motorcycle so that it is vertical after warming
up the engine.

•

Unscrew the oil filler plug [A].

•

Place the oil pan beneath 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 filter
(see Oil Filter Replacement).

•

Replace the drain bolt gasket [B] with a new one.

•

Tighten:

Torque - Engine Oil Drain Bolt: 19.6 N·m (2.00 kgf·m, 14.5

ft·lb)

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Pour in the specified type and amount of oil.

Recommended Engine Oil

Type:

API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2

Viscosity:

SAE 10W-40

Capacity:

2.0 L (2.1 US qt) (when filter is not
removed)
2.2 L (2.3 US qt) (when filter is removed)
2.4 L (2.5 US qt) (when engine is
completely dry)

NOTE

○

Do not add any chemical additive to the oil. Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.

○

Although 10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.

•

Check the oil level (see Oil Level Inspection in the Engine
Lubrication System chapter).

Oil Filter Replacement

•

Drain the engine oil (see Engine Oil Change).

•

Remove the oil filter [A] with the oil filter wrench [B].

Special Tool - Oil Filter Wrench: 57001-1249

•

Replace the filter with a new one.

•

Apply engine oil to the O-ring [A] before installation.

•

Tighten the filter with the oil filter wrench.

Torque - Oil Filter: 17.5 N·m (1.78 kgf·m, 12.9 ft·lb)

NOTE

○

Hand tightening of the oil filter can not be allowed since
it does not reach to this tightening torque.

•

Pour in the specified type and amount of oil (see Engine
Oil Change).

•

Install the removed parts (see appropriate chapters).

PERIODIC MAINTENANCE 2-33

Periodic Maintenance Procedures

Wheels/Tires

Air Pressure Inspection

•

Remove the air valve cap.

•

Measure the tire air pressure with an air pressure gauge
[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).

•

Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.

Air Pressure (when Cold)

Front:

Up to 180 kg (397 lb) load:
200 kPa (2.00 kgf/cm², 28 psi)

Rear:

Up to 180 kg (397 lb) load:
225 kPa (2.25 kgf/cm², 32 psi)

Wheels and Tires

Wheel/Tire Damage Inspection

•

Remove any imbedded stones [A] or other foreign parti-
cles [B] from tread.

•

Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate inter-
nal damage, requiring tire replacement.

•

Visually inspect the wheel for cracks, cuts and dents dam-
age.
If any damage is found, replace the wheel if necessary.

Tire Tread Wear Inspection

As the tire tread wears down, the tire becomes more sus-

ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.

•

Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Tread Depth

Standard:

Front

4.2 mm (0.17 in.)

Rear

6.4 mm (0.25 in.)

Service Limit:

Front

1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)

Rear

2 mm (0.08 in.)
(Up to 130 km/h (80 mph))
3 mm (0.12 in.)
(Over 130 km/h (80 mph))

WARNING

Some replacement tires may adversely affect han-
dling and cause an accident resulting in serious in-
jury or death. To ensure proper handling and sta-
bility, use only the recommended standard tires for
replacement, inflated to the standard pressure.

NOTE

○

Most countries may have their own regulations a mini-
mum tire tread depth: be sure to follow them.

○

Check and balance the wheel when a tire is replaced
with a new one.

Wheel Bearing Damage Inspection

•

Raise the front wheel off the ground with the jack (see
Front Wheel Removal in the Wheels/Tires chapter).

•

Turn the handlebar all the way to the right or left.

•

Inspect the roughness of the front wheel bearing by push-
ing and pulling [A] the wheel.

•

Spin [B] the front wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).

•

Raise the rear wheel off the ground with the stand (see
Rear Wheel Removal in the Wheels/Tires chapter).

•

Inspect the roughness of the rear wheel bearing by push-
ing and pulling [A] the wheel.

•

Spin [B] the rear wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Re-
moval, Hub Bearing Inspection in the Wheels/Tires chap-
ter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).

PERIODIC MAINTENANCE 2-35

Periodic Maintenance Procedures

Final Drive

Drive Chain Lubrication Condition Inspection

•

If a special lubricant is not available, a heavy oil such as
SAE 90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.

•

If the chain appears especially dirty, clean it before lubri-
cation.

NOTICE

The O-rings between the side plates seal in the lu-
bricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubri-
cant, observe the following rules.
Use only kerosene or diesel oil for cleaning of the
O-ring of the drive chain. Any other cleaning solu-
tion such as gasoline will cause deterioration and
swelling of the O-ring. Immediately blow the chain
dry with compressed air after cleaning. Complete
cleaning and drying the chain within 10 minutes.

•

Apply oil to the sides of the rollers so that oil will penetrate
to the rollers and bushings. Apply the oil to the O-rings so
that the O-rings will be coated with oil.

•

Wipe off any excess oil.

Oil Applied Areas [A]
O-rings [B]

Drive Chain Slack Inspection

NOTE

○

Check the slack with the motorcycle setting on its side-
stand.

○

Clean the chain if it is dirty, and lubricate it if it appears
dry.

•

Check the wheel alignment (see Wheel Alignment Inspec-
tion).

•

Rotate the rear wheel to find the position where the chain
is tightest.

•

Measure the vertical movement (chain slack) [A] midway
between the sprockets.
If the chain slack exceeds the standard, adjust it.

Chain Slack

Standard:

∼

30 mm (0.8

∼

1.2 in.)

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Drive Chain Slack Adjustment

•

Remove the cotter pin [A], and loosen the axle nut [B].

•

Loosen the both chain adjuster locknuts [C].
If the chain is too loose, turn out the left and right chain
adjusters [D] evenly.
If the chain is too tight, turn in the left and right chain
adjusters evenly, and kick the wheel forward.

•

Turn both chain adjusters evenly until the drive chain has
the correct amount of slack. To keep the chain and wheel
properly aligned, the notch [E] on the right wheel align-
ment indicator [F] should align with the same swingarm
mark or position [G] that the left indicator notch aligns
with.

WARNING

Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.

•

Tighten both chain adjuster locknuts securely.

•

Tighten:

Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)

•

Turn the wheel, measure the chain slack again at the tight-
est position, and readjust if necessary.

•

Insert a new cotter pin [A].

NOTE

○

When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.

○

It should be within 30 degrees.

○

Loosen once and tighten again when the slot goes past
the nearest hole.

•

Bend the cotter pin [A] over the nut [B].

WARNING

A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.

PERIODIC MAINTENANCE 2-37

Periodic Maintenance Procedures

Wheel Alignment Inspection

•

Check that the notch [A] on the left alignment indicator [B]
aligns with the same swingarm mark or position [C] that
the right alignment indicator notch aligns with.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment).

NOTE

○

Wheel alignment can be also checked using the
straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.

Drive Chain Wear Inspection

•

Remove the chain cover (see Drive Chain Removal in the
Final Drive chapter).

•

Rotate the rear wheel to inspect the drive chain for dam-
aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.

•

Stretch the chain taut by hanging a 10 kg (22 lb) weight
[A] on the chain.

•

Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.

Drive Chain 20-link Length

Standard:

317.5

∼

318.2 mm (12.50

∼

12.53 in.)

Service Limit:

319 mm (12.56 in.)

WARNING

A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. Inspect the chain for
damage and proper adjustment before each ride.
If chain wear exceeds the service limit, replace it
with the standard chain. It is an endless type and
should not be cut for installation.

Standard Chain

Make:

ENUMA
L.G.B. (when shipping)
DAIDO (when shipping) (BR Model)

Type:

EK520SRO
R520HPXR (when shipping)
DID 520VD2 (when shipping) (BR
Model)

Link:

106 links

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Hose and Pipe Damage and Installation Condi-
tion Inspection

•

For models equipped with an ABS, remove the fuel tank
(see Fuel Tank Removal in the Fuel System (DFI) chap-
ter).

•

Inspect the brake hoses and fittings for deterioration,
cracks and signs of leakage.

○

The high pressure inside the brake line can cause fluid to
leak [A] or the hose, pipe (ABS equipped models) to burst
if the line is not properly maintained. Bend and twist the
rubber hose while examining it.
Replace the hose and pipe (ABS equipped models) if any
crack [B], bulge [C] or leakage is noticed.
Tighten any brake hose banjo bolts and brake pipe joint
nuts.

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

(ABS Equipped Models)

•

Inspect the brake hose routing.
If any brake hose and pipe (ABS equipped models) rout-
ing is incorrect, route the brake hose according to Cable,
Wire, and Hose Routing section in the Appendix chapter.

Brake Operation Inspection

•

Inspect the operation of the front and rear brake by run-
ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.

WARNING

When test riding the vehicle, be aware of surround-
ing traffic for your safety.

Brake Fluid Level Inspection

•

Check that the brake fluid level in the front brake reservoir
[A] is above the lower level line [B].

NOTE

○

Hold the reservoir horizontal by turning the handlebar
when checking brake fluid level.

If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C] in the reservoir.

PERIODIC MAINTENANCE 2-41

Periodic Maintenance Procedures

•

Check that the brake fluid level in the rear brake reservoir
[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].

WARNING

Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an ac-
cident resulting in injury or death. Do not mix two
brands of brake fluid. Change the brake fluid in the
brake line completely if the brake fluid must be re-
filled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.

Recommended Disc Brake Fluid

Grade:

Front

DOT3 or DOT4

Rear

DOT4

•

Follow procedure below to install the rear brake fluid
reservoir cap correctly.

○

First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].

Brake Fluid Change

NOTE

○

The procedure to change the front brake fluid is as fol-
lows. Changing the rear brake fluid is the same as for
the front brake.

•

Level the brake fluid reservoir.

•

Remove the reservoir cap and diaphragm.

•

Remove the rubber cap [A] from the bleed valve on the
caliper.

•

Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.

•

Fill the reservoir with fresh specified brake fluid.

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Change the brake fluid.

○

Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].

NOTE

○

The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.

•

Remove the clear plastic hose.

•

Install the diaphragm and reservoir cap.

•

Tighten:

Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

•

Follow the procedure below to install the rear brake fluid
reservoir cap correctly.

○

•

Tighten the bleed valve, and install the rubber cap.

Torque - Bleed Valve: 5.5 N·m (0.56 kgf·m, 49 in·lb)

•

After changing the fluid, check the brake for good braking
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.

PERIODIC MAINTENANCE 2-43

Periodic Maintenance Procedures

Brake Hose and Pipe Replacement

NOTICE

Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.

•

Remove the brake hose banjo bolts [A].

•

Remove the brake hoses [B], noting the following.

○

Take care not to spill the brake fluid on the painted or
plastic parts.

○

Temporarily secure the end of the brake hose to some
high place to keep fluid loss to a minimum.

•

For models equipped with an ABS, note the following.

NOTE

○

When removing the brake pipes and hoses on the hy-
draulic unit, remove them according to each assembly
of the exploded view in the Brakes chapter.

•

Remove:

Right Middle Fairing (see Middle Side Fairing Removal
in the Frame chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Bracket Bolts [A]
Brackets [B]
Brake Pipe Joint Nuts [C]

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Install the brake hose, noting the following.

○

Replace the washers [A] on each side of hose fitting [B]
with new ones.

○

Avoid sharp bending, kinking, flattening or twisting, and
route the hoses according to Cable, Wire, and Hose Rout-
ing section in the Appendix chapter.

•

Before installing the brake pipe, check to see that there is
no damage on the threads of the brake pipe joint nut.
If there is any damage, replace the damaged parts with
new ones.

NOTE

○

Tighten the brake pipe joint nuts at both ends of the
brake pipe temporarily and then tighten them to the
specified torque.

•

Install the brake pipes at the specified angle (see Cable,
Wire, and Hose Routing section in the Appendix chapter).

•

Tighten the brake pipe joint nuts with the flare nut wrench.

•

Tighten:

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

Brake Pipe Joint Nuts (ABS Equipped Models): 18

N·m (1.8 kgf·m, 13 ft·lb)

•

Fill the brake line (see Brake Fluid Change).

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

•

Remove the front master cylinder (see Front Master Cylin-
der Removal in the Brakes chapter).

•

Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.

•

Unscrew the locknut and pivot bolt, and remove the brake
lever.

•

Pull the dust cover out of place, and remove the circlip.

Special Tool - Inside Circlip Pliers: 57001-143

•

Remove the piston [A], secondary cup [B], primary cup
[C] and return spring [D].

NOTICE

Do not remove the secondary cup from the piston
since removal will damage it.

PERIODIC MAINTENANCE 2-45

Periodic Maintenance Procedures

Rear Master Cylinder Disassembly

NOTE

○

Do not remove the push rod clevis for master cylinder
disassembly since removal requires brake position ad-
justment.

•

Remove the rear master cylinder (see Rear Master Cylin-
der Removal in the Brakes chapter).

•

Remove the circlip [A].

Special Tool - Inside Circlip Pliers: 57001-143

•

Remove the push rod with the piston stop.

•

Take off the piston [B], secondary cup [C], primary cup [D]
and return spring [E].

•

Remove the circlip [F] and pull out the brake hose con-
nector [G] and O-ring [H].

Special Tool - Inside Circlip Pliers: 57001-143

NOTICE

Do not remove the secondary cup from the piston
since removal will damage it.

Master Cylinder Assembly

•

Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.

NOTICE

Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be diffi-
cult to wash off completely, and will eventually de-
teriorate the rubber used in the disc brake.

•

Apply brake fluid to the new parts and to the inner wall of
the cylinder.

•

Take care not to scratch the piston or the inner wall of the
cylinder.

•

Apply silicone grease to the brake lever pivot bolt and
push rod.

•

Tighten:

Torque - Brake Lever Pivot Bolt: 5.9 N·m (0.60 kgf·m, 52

in·lb)

Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60

kgf·m, 52 in·lb)

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Caliper Rubber Parts Replacement

NOTE

○

The procedure to assembly/disassembly the front
caliper is as follows. Assembling/disassembling the
rear caliper is the same as for the front caliper.

Caliper Disassembly

•

Remove:

Front/Rear Caliper (see Front/Rear Caliper Removal in
the Brakes chapter)
Brake Pads (see Brake Pad Removal in the Brakes
chapter)
Pad Spring

•

Using compressed air, remove the pistons.

○

Cover the piston area with a clean, thick cloth [A].

○

Blow compressed air [B] into the hole for the banjo bolt to
remove the piston.

WARNING

The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.

•

Remove the pistons by hand.

•

Remove:

Caliper Holder
Dust Seals
Fluid Seals
Bleed Valve
Rubber Cap

NOTE

○

If compressed air is not available, do as follows with the
brake hose connected to the caliper.

○

Prepare a container for brake fluid, and perform the
work above it.

○

Remove the pads (see Brake Pad Removal in the
Brakes chapter).

○

Pump the brake lever until the pistons come out of the
cylinders, and then disassemble the caliper.

Caliper Assembly

•

Clean the caliper parts except for the pads.

NOTICE

For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.

•

Install the bleed valve and rubber cap.

Torque - Bleed Valve: 5.5 N·m (0.56 kgf·m, 49 in·lb)

PERIODIC MAINTENANCE 2-47

Periodic Maintenance Procedures

•

Apply brake fluid to the cylinder bores.

•

Replace the fluid seals [A] with new ones.

○

Apply silicone grease to the fluid seals, and install them
into the cylinders by hand.

•

Replace the dust seals [B] with new ones.

•

Apply brake fluid to the outside of the pistons, and push
them into each cylinder by hand.

•

Check the dust cover [A] and the friction boot [B] replace
them with new ones if they are damaged.

•

Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to
the caliper holder pin bolts [C] (PBC is a special high
-temperature, water-resistance grease).

•

Install the caliper holder and pad spring.

•

Install the pads (see Brake Pad Installation in the Brakes
chapter).

•

Wipe up any spilled brake fluid on the caliper with wet
cloth.

Brake Pad Wear Inspection

•

Remove the brake pads (see Brake Pad Removal in the
Brakes chapter).

•

Check the lining thickness [A] of the pads in each caliper.
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.

Pad Lining Thickness

Standard:

Front

4.5 mm (0.18 in.)

Rear

4.5 mm (0.18 in.)

Service Limit:

Front

1.5 mm (0.06 in.)
1 mm (0.04 in.)
(ABS Equipped Models)

Rear

1.5 mm (0.06 in.)

Brake Light Switch Operation Inspection

•

Turn on the ignition switch.

•

The brake light [A] should go on when the brake lever is
applied or after the brake pedal is depressed about 10
mm (0.39 in.).

Kawasaki Ninja 300 / Ninja 300 ABS Motorcycle. Service Manual (2013) - page 2