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Kawasaki Ninja 300 - User Manual

Kawasaki Ninja 300
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Ninja 300
Ninja 300 ABS
Motorcycle
Service Manual

Table of Contents

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Summary

Emission Control Information

Crankcase Emission Control System

Details the system designed to prevent crankcase vapor release into the atmosphere.

Exhaust Emission Control System

Describes the system that reduces pollutants discharged by the exhaust.

Evaporative Emission Control System

Outlines the system that prevents fuel vapors from venting into the atmosphere.

Tampering with Noise Control System Prohibited

Foreword

How to Use This Manual

Guidance on navigating the manual's structure and understanding its symbols.

General Information

Before Servicing

Crucial precautions and procedures to follow before performing any inspection or disassembly.

Model Identification

Information to identify specific motorcycle models, including visual views.

General Specifications

Detailed technical specifications for various motorcycle systems.

Technical Information - Assist and Slipper Clutch

Explains the function and components of the assist and slipper clutch mechanism.

Periodic Maintenance

Periodic Maintenance Chart

A detailed chart outlining maintenance intervals for various items based on time and mileage.

Torque and Locking Agent

Lists tightening torques and recommended locking agents for major fasteners.

Specifications

Provides standard and service limit specifications for various motorcycle components.

Special Tools

Lists and illustrates specific tools required for certain maintenance procedures.

Periodic Maintenance Procedures

Step-by-step instructions for performing scheduled maintenance tasks.

Fuel System (DFI)

Exploded View

Visual representation of fuel system components and their relationships.

DFI System

Overview and explanation of the Digital Fuel Injection system's operation.

Specifications

Technical data and standards for fuel system components and functions.

Special Tools and Sealant

Lists specialized tools and sealants for fuel system servicing.

DFI Servicing Precautions

Important safety and handling precautions for servicing the DFI system.

Troubleshooting the DFI System

Guide to diagnosing and resolving common problems within the DFI system.

Cooling System

Exploded View

Visual breakdown of cooling system components.

Specifications

Technical data for cooling system components like coolant and thermostat.

Coolant

Procedures for inspecting, draining, filling, and testing the coolant.

Cooling System Flushing

Steps for cleaning the cooling system to remove deposits.

Coolant Reserve Tank

Procedures for removing and installing the coolant reserve tank.

Water Pump

Detailed instructions for water pump removal, installation, and inspection.

Radiator

Procedures for removing, installing, and inspecting the radiator and fan.

Thermostat

Instructions for removing, installing, and inspecting the thermostat.

Hoses and Pipes

Guidance on installing and inspecting hoses and pipes in the cooling system.

Water Temperature Sensor

Procedures for removing, installing, and inspecting the water temperature sensor.

Engine Top End

Exploded View

Visual breakdown of the engine's top-end components.

Specifications

Detailed technical specifications for camshafts, cylinder head, valves, and pistons.

Special Tools and Sealant

Lists specialized tools and sealants required for top-end engine work.

Clean Air System

Procedures for servicing the clean air system components like valves and hoses.

Cylinder Head Cover

Instructions for removing, installing, and inspecting the cylinder head cover.

Camshaft Chain Tensioner

Procedures for removing, installing, and inspecting the camshaft chain tensioner.

Camshaft, Camshaft Chain

Detailed steps for removing and installing camshafts and the camshaft chain.

Cylinder Head

Procedures for removing, installing, and inspecting the cylinder head and its components.

Valves

Comprehensive guide to valve clearance, removal, installation, and seat repair.

Cylinder, Pistons

Procedures for removing, installing, and inspecting cylinders, pistons, and rings.

Muffler

Instructions for removing, installing, and inspecting the muffler assembly.

Clutch

Exploded View

Visual breakdown of clutch components.

Specifications

Technical data for clutch components like plate thickness and spring length.

Special Tool and Sealant

Lists specialized tools and sealants for clutch servicing.

Clutch Lever and Cable

Procedures for inspecting, adjusting, removing, and installing the clutch lever and cable.

Clutch Cover

Instructions for removing, installing, and disassembling the clutch cover.

Clutch

Detailed steps for removing and installing the clutch assembly, plates, and springs.

Clutch Plate Wear and Damage Inspection

Methods for inspecting clutch plates for wear, damage, and warp.

Clutch Housing Spline Inspection

Inspection of clutch housing splines for wear.

Clutch Pressure Plate and Clutch Hub Inspection

Inspection of contact areas on clutch pressure plate and hub.

Engine Lubrication System

Exploded View

Visual breakdown of the engine lubrication system components.

Engine Oil Flow Chart

Diagram illustrating the path of oil through the engine lubrication system.

Specifications

Technical data for engine oil type, viscosity, capacity, and oil pressure.

Special Tools and Sealant

Lists specialized tools and sealants for lubrication system servicing.

Engine Oil and Oil Filter

Procedures for checking oil level, changing engine oil, and replacing the oil filter.

Oil Pan

Instructions for removing and installing the oil pan.

Oil Screen

Procedures for removing, installing, and cleaning the oil screen.

Oil Pressure Relief Valve

Instructions for removing, installing, and inspecting the oil pressure relief valve.

Oil Pump

Detailed steps for removing, installing, and assembling the oil pump.

Oil Pressure Measurement

Procedure for measuring engine oil pressure.

Oil Pressure Switch

Procedures for removing, installing, and inspecting the oil pressure switch.

Engine Removal;Installation

Exploded View

Visual breakdown of engine mounting components.

Engine Removal

Step-by-step instructions for safely removing the engine from the motorcycle.

Engine Installation

Step-by-step instructions for correctly installing the engine back into the motorcycle.

Crankshaft;Transmission

Exploded View

Visual breakdown of crankshaft, connecting rods, and transmission components.

Specifications

Technical data for crankshaft, connecting rods, and transmission parts.

Special Tools and Sealant

Lists specialized tools and sealants for crankshaft and transmission servicing.

Crankcase

Procedures for splitting, assembling, and inspecting the crankcase.

Crankshaft and Connecting Rods

Detailed steps for removing, installing, cleaning, and inspecting crankshaft and connecting rods.

Connecting Rod Installation

Procedures for installing connecting rods, including bearing selection.

Connecting Rod Big End Bearing Insert;Crankpin Wear Inspection

Methods for inspecting connecting rod bearing and crankpin wear.

Crankshaft Side Clearance Inspection

Procedure for measuring crankshaft side clearance.

Crankshaft Runout Inspection

Method for measuring crankshaft runout.

Crankshaft Main Bearing Insert;Journal Wear Inspection

Procedures for inspecting crankshaft main bearing and journal wear.

Starter Motor Clutch

Removal, installation, inspection, and disassembly of the starter motor clutch.

Balancer

Procedures for removing, installing, and inspecting the balancer shaft and bearings.

Transmission

Comprehensive guide to servicing the transmission, including shift pedals, drums, and forks.

Shift Drum and Fork

Procedures for removing, installing, and inspecting the shift drum and forks.

Shift Fork;Gear Groove Wear Inspection

Inspection of shift fork and gear groove wear.

Wheels;Tires

Exploded View

Visual breakdown of wheel and tire assembly components.

Specifications

Technical data for wheel rim runout, tire pressure, tread depth, and standard tire sizes.

Special Tools

Lists specialized tools required for wheel and tire servicing.

Wheels (Rims)

Procedures for removing, installing, inspecting, and balancing front and rear wheels.

Tires

Instructions for tire inspection, removal, installation, and repair.

Hub Bearing

Procedures for removing, installing, inspecting, and lubricating hub bearings.

Final Drive

Exploded View

Visual breakdown of final drive components.

Specifications

Technical data for drive chain slack, wear, type, and sprocket warp.

Special Tool

Lists specialized tools for final drive servicing.

Drive Chain

Procedures for drive chain inspection, adjustment, lubrication, removal, and replacement.

Sprocket, Coupling

Instructions for installing sprockets, coupling, and inspecting bearings and dampers.

Brakes

Exploded View

Visual breakdown of front brake system components.

Specifications

Technical data for brake levers, pads, discs, and fluid.

Special Tools

Lists specialized tools for brake system servicing.

Brake Pedal

Procedures for inspecting, adjusting, removing, and installing the brake pedal.

Calipers

Instructions for removing, installing, disassembling, and inspecting brake calipers.

Brake Pads

Procedures for removing, installing, and inspecting brake pads for wear.

Master Cylinder

Detailed steps for removing, installing, disassembling, and inspecting master cylinders.

Brake Disc

Procedures for removing, installing, and inspecting brake discs for wear and warp.

Brake Fluid

Information on brake fluid level inspection, change, and line bleeding.

Brake Hose

Procedures for removing, installing, and inspecting brake hoses.

Anti-Lock Brake System (Equipped Models)

Information specific to ABS systems, including parts location, precautions, and troubleshooting.

Suspension

Exploded View

Visual breakdown of front fork and rear shock absorber components.

Specifications

Technical data for front fork and rear shock absorber settings and oil.

Special Tools

Lists specialized tools for suspension servicing.

Front Fork

Comprehensive guide to front fork removal, installation, oil change, and disassembly.

Rear Shock Absorber

Procedures for adjusting spring preload, removing, installing, and inspecting the rear shock absorber.

Swingarm

Instructions for removing, installing, and inspecting the swingarm and its bearings.

Tie-Rod, Rocker Arm

Procedures for removing, installing, and inspecting tie-rods and rocker arms.

Steering

Exploded View

Visual breakdown of steering system components.

Special Tools

Lists specialized tools for steering system servicing.

Steering

Procedures for steering inspection and adjustment.

Steering Stem

Detailed instructions for removing, installing, lubricating, and inspecting the steering stem and bearings.

Handlebar

Procedures for removing, installing, and tightening handlebar components.

Frame

Exploded View

Visual breakdown of frame components and mounting hardware.

Seats

Procedures for removing and installing the front and rear seats.

Fairings

Instructions for removing and installing various fairing panels like lower, inner, and middle fairings.

Fenders

Procedures for removing and installing front and rear fenders.

Frame

Procedure for inspecting the frame for damage.

Sidestand

Procedures for removing and installing the sidestand and its switch.

Electrical System

Exploded View

Visual breakdown of electrical system components.

Specifications

Technical data for battery, charging system, ignition, and starter motor.

Special Tools and Sealant

Lists specialized tools and sealants for electrical system servicing.

Parts Location

Identifies the location of key electrical components on the motorcycle.

Wiring Diagram (EX300 A without GPS Unit)

Detailed wiring diagram for models without GPS unit.

Precautions

Essential safety and handling precautions for electrical system servicing.

Electrical Wiring

Procedures for inspecting the main harness and connectors.

Battery

Instructions for battery removal, installation, activation, charging, and inspection.

Charging System

Procedures for inspecting the alternator, stator, and regulator/rectifier.

Ignition System

Covers crankshaft sensor, stick coils, and spark plug inspection and service.

Electric Starter System

Procedures for starter motor removal, installation, disassembly, and assembly.

Lighting System

Instructions for headlight, city light, tail/brake light, and turn signal bulb replacement.

Switches and Sensors

Procedures for inspecting and testing various switches and sensors.

Relay Box

Instructions for removing, installing, and inspecting the relay box and its circuits.

Fuse

Procedures for fuse removal, installation, and inspection.

Appendix

Cable, Wire, and Hose Routing

Illustrates the correct routing of cables, wires, and hoses throughout the motorcycle.

Troubleshooting Guide

A comprehensive guide to diagnosing and resolving various motorcycle issues.

Summary

Emission Control Information

Crankcase Emission Control System

Details the system designed to prevent crankcase vapor release into the atmosphere.

Exhaust Emission Control System

Describes the system that reduces pollutants discharged by the exhaust.

Evaporative Emission Control System

Outlines the system that prevents fuel vapors from venting into the atmosphere.

Tampering with Noise Control System Prohibited

Foreword

How to Use This Manual

Guidance on navigating the manual's structure and understanding its symbols.

General Information

Before Servicing

Crucial precautions and procedures to follow before performing any inspection or disassembly.

Model Identification

Information to identify specific motorcycle models, including visual views.

General Specifications

Detailed technical specifications for various motorcycle systems.

Technical Information - Assist and Slipper Clutch

Explains the function and components of the assist and slipper clutch mechanism.

Periodic Maintenance

Periodic Maintenance Chart

A detailed chart outlining maintenance intervals for various items based on time and mileage.

Torque and Locking Agent

Lists tightening torques and recommended locking agents for major fasteners.

Specifications

Provides standard and service limit specifications for various motorcycle components.

Special Tools

Lists and illustrates specific tools required for certain maintenance procedures.

Periodic Maintenance Procedures

Step-by-step instructions for performing scheduled maintenance tasks.

Fuel System (DFI)

Exploded View

Visual representation of fuel system components and their relationships.

DFI System

Overview and explanation of the Digital Fuel Injection system's operation.

Specifications

Technical data and standards for fuel system components and functions.

Special Tools and Sealant

Lists specialized tools and sealants for fuel system servicing.

DFI Servicing Precautions

Important safety and handling precautions for servicing the DFI system.

Troubleshooting the DFI System

Guide to diagnosing and resolving common problems within the DFI system.

Cooling System

Exploded View

Visual breakdown of cooling system components.

Specifications

Technical data for cooling system components like coolant and thermostat.

Coolant

Procedures for inspecting, draining, filling, and testing the coolant.

Cooling System Flushing

Steps for cleaning the cooling system to remove deposits.

Coolant Reserve Tank

Procedures for removing and installing the coolant reserve tank.

Water Pump

Detailed instructions for water pump removal, installation, and inspection.

Radiator

Procedures for removing, installing, and inspecting the radiator and fan.

Thermostat

Instructions for removing, installing, and inspecting the thermostat.

Hoses and Pipes

Guidance on installing and inspecting hoses and pipes in the cooling system.

Water Temperature Sensor

Procedures for removing, installing, and inspecting the water temperature sensor.

Engine Top End

Exploded View

Visual breakdown of the engine's top-end components.

Specifications

Detailed technical specifications for camshafts, cylinder head, valves, and pistons.

Special Tools and Sealant

Lists specialized tools and sealants required for top-end engine work.

Clean Air System

Procedures for servicing the clean air system components like valves and hoses.

Cylinder Head Cover

Instructions for removing, installing, and inspecting the cylinder head cover.

Camshaft Chain Tensioner

Procedures for removing, installing, and inspecting the camshaft chain tensioner.

Camshaft, Camshaft Chain

Detailed steps for removing and installing camshafts and the camshaft chain.

Cylinder Head

Procedures for removing, installing, and inspecting the cylinder head and its components.

Valves

Comprehensive guide to valve clearance, removal, installation, and seat repair.

Cylinder, Pistons

Procedures for removing, installing, and inspecting cylinders, pistons, and rings.

Muffler

Instructions for removing, installing, and inspecting the muffler assembly.

Clutch

Exploded View

Visual breakdown of clutch components.

Specifications

Technical data for clutch components like plate thickness and spring length.

Special Tool and Sealant

Lists specialized tools and sealants for clutch servicing.

Clutch Lever and Cable

Procedures for inspecting, adjusting, removing, and installing the clutch lever and cable.

Clutch Cover

Instructions for removing, installing, and disassembling the clutch cover.

Clutch

Detailed steps for removing and installing the clutch assembly, plates, and springs.

Clutch Plate Wear and Damage Inspection

Methods for inspecting clutch plates for wear, damage, and warp.

Clutch Housing Spline Inspection

Inspection of clutch housing splines for wear.

Clutch Pressure Plate and Clutch Hub Inspection

Inspection of contact areas on clutch pressure plate and hub.

Engine Lubrication System

Exploded View

Visual breakdown of the engine lubrication system components.

Engine Oil Flow Chart

Diagram illustrating the path of oil through the engine lubrication system.

Specifications

Technical data for engine oil type, viscosity, capacity, and oil pressure.

Special Tools and Sealant

Lists specialized tools and sealants for lubrication system servicing.

Engine Oil and Oil Filter

Procedures for checking oil level, changing engine oil, and replacing the oil filter.

Oil Pan

Instructions for removing and installing the oil pan.

Oil Screen

Procedures for removing, installing, and cleaning the oil screen.

Oil Pressure Relief Valve

Instructions for removing, installing, and inspecting the oil pressure relief valve.

Oil Pump

Detailed steps for removing, installing, and assembling the oil pump.

Oil Pressure Measurement

Procedure for measuring engine oil pressure.

Oil Pressure Switch

Procedures for removing, installing, and inspecting the oil pressure switch.

Engine Removal;Installation

Exploded View

Visual breakdown of engine mounting components.

Engine Removal

Step-by-step instructions for safely removing the engine from the motorcycle.

Engine Installation

Step-by-step instructions for correctly installing the engine back into the motorcycle.

Crankshaft;Transmission

Exploded View

Visual breakdown of crankshaft, connecting rods, and transmission components.

Specifications

Technical data for crankshaft, connecting rods, and transmission parts.

Special Tools and Sealant

Lists specialized tools and sealants for crankshaft and transmission servicing.

Crankcase

Procedures for splitting, assembling, and inspecting the crankcase.

Crankshaft and Connecting Rods

Detailed steps for removing, installing, cleaning, and inspecting crankshaft and connecting rods.

Connecting Rod Installation

Procedures for installing connecting rods, including bearing selection.

Connecting Rod Big End Bearing Insert;Crankpin Wear Inspection

Methods for inspecting connecting rod bearing and crankpin wear.

Crankshaft Side Clearance Inspection

Procedure for measuring crankshaft side clearance.

Crankshaft Runout Inspection

Method for measuring crankshaft runout.

Crankshaft Main Bearing Insert;Journal Wear Inspection

Procedures for inspecting crankshaft main bearing and journal wear.

Starter Motor Clutch

Removal, installation, inspection, and disassembly of the starter motor clutch.

Balancer

Procedures for removing, installing, and inspecting the balancer shaft and bearings.

Transmission

Comprehensive guide to servicing the transmission, including shift pedals, drums, and forks.

Shift Drum and Fork

Procedures for removing, installing, and inspecting the shift drum and forks.

Shift Fork;Gear Groove Wear Inspection

Inspection of shift fork and gear groove wear.

Wheels;Tires

Exploded View

Visual breakdown of wheel and tire assembly components.

Specifications

Technical data for wheel rim runout, tire pressure, tread depth, and standard tire sizes.

Special Tools

Lists specialized tools required for wheel and tire servicing.

Wheels (Rims)

Procedures for removing, installing, inspecting, and balancing front and rear wheels.

Tires

Instructions for tire inspection, removal, installation, and repair.

Hub Bearing

Procedures for removing, installing, inspecting, and lubricating hub bearings.

Final Drive

Exploded View

Visual breakdown of final drive components.

Specifications

Technical data for drive chain slack, wear, type, and sprocket warp.

Special Tool

Lists specialized tools for final drive servicing.

Drive Chain

Procedures for drive chain inspection, adjustment, lubrication, removal, and replacement.

Sprocket, Coupling

Instructions for installing sprockets, coupling, and inspecting bearings and dampers.

Brakes

Exploded View

Visual breakdown of front brake system components.

Specifications

Technical data for brake levers, pads, discs, and fluid.

Special Tools

Lists specialized tools for brake system servicing.

Brake Pedal

Procedures for inspecting, adjusting, removing, and installing the brake pedal.

Calipers

Instructions for removing, installing, disassembling, and inspecting brake calipers.

Brake Pads

Procedures for removing, installing, and inspecting brake pads for wear.

Master Cylinder

Detailed steps for removing, installing, disassembling, and inspecting master cylinders.

Brake Disc

Procedures for removing, installing, and inspecting brake discs for wear and warp.

Brake Fluid

Information on brake fluid level inspection, change, and line bleeding.

Brake Hose

Procedures for removing, installing, and inspecting brake hoses.

Anti-Lock Brake System (Equipped Models)

Information specific to ABS systems, including parts location, precautions, and troubleshooting.

Suspension

Exploded View

Visual breakdown of front fork and rear shock absorber components.

Specifications

Technical data for front fork and rear shock absorber settings and oil.

Special Tools

Lists specialized tools for suspension servicing.

Front Fork

Comprehensive guide to front fork removal, installation, oil change, and disassembly.

Rear Shock Absorber

Procedures for adjusting spring preload, removing, installing, and inspecting the rear shock absorber.

Swingarm

Instructions for removing, installing, and inspecting the swingarm and its bearings.

Tie-Rod, Rocker Arm

Procedures for removing, installing, and inspecting tie-rods and rocker arms.

Steering

Exploded View

Visual breakdown of steering system components.

Special Tools

Lists specialized tools for steering system servicing.

Steering

Procedures for steering inspection and adjustment.

Steering Stem

Detailed instructions for removing, installing, lubricating, and inspecting the steering stem and bearings.

Handlebar

Procedures for removing, installing, and tightening handlebar components.

Frame

Exploded View

Visual breakdown of frame components and mounting hardware.

Seats

Procedures for removing and installing the front and rear seats.

Fairings

Instructions for removing and installing various fairing panels like lower, inner, and middle fairings.

Fenders

Procedures for removing and installing front and rear fenders.

Frame

Procedure for inspecting the frame for damage.

Sidestand

Procedures for removing and installing the sidestand and its switch.

Electrical System

Exploded View

Visual breakdown of electrical system components.

Specifications

Technical data for battery, charging system, ignition, and starter motor.

Special Tools and Sealant

Lists specialized tools and sealants for electrical system servicing.

Parts Location

Identifies the location of key electrical components on the motorcycle.

Wiring Diagram (EX300 A without GPS Unit)

Detailed wiring diagram for models without GPS unit.

Precautions

Essential safety and handling precautions for electrical system servicing.

Electrical Wiring

Procedures for inspecting the main harness and connectors.

Battery

Instructions for battery removal, installation, activation, charging, and inspection.

Charging System

Procedures for inspecting the alternator, stator, and regulator/rectifier.

Ignition System

Covers crankshaft sensor, stick coils, and spark plug inspection and service.

Electric Starter System

Procedures for starter motor removal, installation, disassembly, and assembly.

Lighting System

Instructions for headlight, city light, tail/brake light, and turn signal bulb replacement.

Switches and Sensors

Procedures for inspecting and testing various switches and sensors.

Relay Box

Instructions for removing, installing, and inspecting the relay box and its circuits.

Fuse

Procedures for fuse removal, installation, and inspection.

Appendix

Cable, Wire, and Hose Routing

Illustrates the correct routing of cables, wires, and hoses throughout the motorcycle.

Troubleshooting Guide

A comprehensive guide to diagnosing and resolving various motorcycle issues.

Kawasaki Ninja 300 Specifications

General IconGeneral
Engine TypeLiquid-cooled, 4-stroke Parallel Twin
Displacement296 cc
Cooling SystemLiquid-cooled
Bore x Stroke62.0 x 49.0 mm
Compression Ratio10.6:1
IgnitionTCBI with digital advance
StartingElectric
Transmission6-speed, return shift
Final DriveSealed chain
Front Suspension37 mm telescopic fork
Front Tire110/70-17
Rear Tire140/70-17
Overall Length2, 015 mm
Overall Width715 mm
Overall Height1, 110 mm
Wheelbase1, 405 mm
Ground Clearance140 mm
Seat Height785 mm
Curb Weight172 kg
Curb Mass172 kg
Maximum Torque27 Nm @ 10, 000 rpm
Fuel SystemFuel injection: ø32 mm x 2
Frame TypeTubular diamond steel
Rear SuspensionBottom-Link Uni-Trak with 5-way adjustable preload
Front BrakesSingle 290 mm petal-type disc with 2-piston caliper
Rear BrakesSingle 220 mm petal-type disc with 2-piston caliper
Fuel Capacity17 liters
Maximum Power39 hp (29 kW) @ 11, 000 rpm

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