Accessories DNA airfilter Gear & Products Kenma Australia Ninja 400 Project Ninja 400 Staff Bikes Technology Workshop

Tech Tips: Project Ninja 400 DNA Air Filter Fitment

DNA Air Filter fitment - Ninja 400

We match a DNA Efficiency air filter to our Lengthy Time period Undertaking Ninja 400, so future providers will simply require it’s cleaned and re-oiled, somewhat than completely changed. Phrases: Kris Hodgson

We’ve simply had a DNA Efficiency Air Filter arrive for our Challenge Ninja 400 and it’s time for fitment, which on the Ninja 400 is a comparatively straightforward and painless job. We haven’t had an opportunity to dyno the bike so we gained’t have that comparability sadly, nevertheless it’s not a mod we do purely for energy or torque positive factors.

The final DNA Air Filter we fitted to a long run undertaking bike noticed some average features alongside a Stage 2 airbox mod, nevertheless on this case the large benefit we’re taking a look at is the long run worth of the DNA air filter, which might be cleaned and reused, with a lifetime guarantee.

That is additionally an amazing DIY job for brand spanking new riders with primary mechanical expertise who need to get to know their bike a bit bit higher. Lifting the tank varies by mannequin, however it’s an excellent job to be conversant in.

On our Challenge Ninja 400 lifting the tank is straightforward, and could be executed with out absolutely eradicating the fairings. One factor to remember is that on this mannequin, pulling the tank up truly includes completely eradicating the tank. It’s held in place into two rubber grommets on the entrance and bolted down on the rear. Some bikes permit the tank to easily be unbolted close to the steering head and pivoted up, with out full removing.

DNA air filter – verify

On the Ninja in eradicating the tank we do additionally have to be cautious, there’s a breather and overflow pipe on the left of the tank, and the gasoline line and connector, in addition to the gasoline pump connector. You’ll want needle nostril pliers for the wire hose clamps and an extended skinny screw driver is useful for releasing the catch on the gasoline pump connector.

In any other case you’ll simply want a metric socket set, Allen/Hex keys (ideally T-bar), and Phillips head screw driver for the screws on the airbox. I like to recommend ensuring you’ve received good high quality instruments too, as stripping any of those bolts or screws might be annoying in the long run.

Equally (perhaps moreso) essential than good instruments can also be having an space to put the undertank panels you take away and the tank! Sure whenever you take away the tank you might want to have a ready space to put it, with a number of layers of sentimental material, like a few towels. The world being out of the best way so that you don’t journey over something can also be essential. Repairing a tank is dear and pointless whenever you’ve broken it doing this type of job!

The Kawasaki tank gained’t leak stored within the regular orientation it sits on the bike, even with the gasoline line disconnected, however there’ll be a tiny preliminary leak whenever you disconnect that line, attempt to catch it with an previous material you possibly can throw away. Additionally organise every bolt and screw as you take away them, so getting the whole lot again in place is fast and straightforward.

Right here’s a step-by-step information:

Ninja 400 DNA Air Filter fitment

Alright, seize that air filter and take it out of the field, verify it’s in your mannequin (in all probability ought to have finished this when it arrived) as you’re going to wrestle afterward if it’s not.

Take away the pillion seat and rider seat for entry to the tank bolt down factors, in addition to the rear mounting factors for the under-tank panels (black textured plastic, not the complete fairings).

Take away the bolts on the under-tank panels, as a basic rule lay them out so you realize what goes again in the place, in case there are totally different size bolts.

Take away the under-tank panel, it has a number of plastic barbs that go into rubber grommets, so it sticks in place, mild strain will pull them lose. On the entrance of the bike it additionally sits with a small part into the fairing panel, go from rear to entrance and it’ll come off simply. Do all these steps on each side.

Now undo the bolts that safe the fairings to the tank (left picture), and the push-pins that additionally maintain every thing collectively. I do that so I’ve obtained a bit extra freeplay within the fairing panels.

Okay left aspect of the tank (dealing with entrance of the bike from the seat) you’ll observe these two rubber pipes onto the tank. One or each is an overflow, the opposite could also be a breather. I’ve observed the tank pressurises although. Both method these want disconnecting. The picture on the best is the fuse field, should you’ve ever had electrical issues you’re accustomed to it. Should you’re unfamiliar with it, thank your fortunate stars. It’s not necessary on this article however value noting the situation and ease of entry. Good work Kawasaki!

Use these needle nostril pliers to loosen and transfer the wire hose clamps. Then disconnect each pipes, they shouldn’t go anyplace, and observe which is which.

OK, we’re making progress, undo these two rear bolts on the tank. At this factors it’s held in place by the 2 grommets on the entrance, close to the headstock. BUT, it’s additionally nonetheless related to the gasoline line and the gasoline pump electrical connector. As a fast notice, the electrical connectors could be annoying in tight areas, however don’t drive them, it’s all about finesse.

DNA Air Filter fitment - Ninja 400

Right here’s the gasoline line disconnected

The gasoline line is very easy to disconnect, simply put a thick rag beneath to catch any gasoline that escapes, a tiny quantity did once I did this a part of the job. The pink clip can simply be pushed up, unlocking the connector. The gasoline tank didn’t leak for me after I disconnected this plug and neither did this line.

Now it’s only a matter of sliding the tank again off the 2 grommets within the entrance of the body, which you’ll see in the correct hand picture. Primarily the entire tank is mounted into these two grommets, with two bolts underneath the rider’s seat holding all the things safe. Clearly on the entrance that’s mounting into rubber, which is why the tank could be a good place to mount your GoPro!

With the tank eliminated put it someplace protected. I positioned it on a number of layers of painters drop sheet, so there was no probability of denting, scratching or abrasion putting it on the bottom or a tabletop. I apparently forgot to take a pic of that too, however you get the thought…

Observe all of the screws across the airbox lid to make it hermetic. All these must be eliminated (clearly), simply be sure to don’t miss any and attempt to pressure the lid open. Additionally, little or no pressure is required for something airbox associated.

Undo all these screws, and ensure if any are totally different lengths you realize the place they go. They have been all the identical on the Ninja 400. Pull that lid off and have a look inside. Now could also be a good time to do a social media replace for all of your mates, to allow them to be suitably impressed by your primary wrenching expertise. It also needs to go with out saying, don’t drop something down these intakes.

The filter is bolted in as you’ll see. Some are merely held in place by the airbox design and a lip, this one has a screw on the rear of the filter, which is the place you’ll notice the discolouring of the inventory filter. Clearly Kawasaki needed to make sure the filter was stored in place snuggly at that time, the place the precise airbox lid itself isn’t holding it there.

The brand new DNA Efficiency air filter! What orientation does it mount? Straightforward one to reply. It has a captive screw identical to the inventory filter, it’ll solely match a method correctly. Notice the screw on the best.

Get the DNA air filter into place then tighten that screw up when you’re positive it’s correctly aligned. It ought to slot in just like the piece of a puzzle. Additionally notice the airbox lid and the lip, that’s to carry the air filter in place and seal the airbox as soon as the screws are again in.

Get all these screws again into the airbox and ensure you haven’t missed any. Now tighten all of them up. It’s SUPER essential, NOT to overtighten these screws. They’re a metallic screw right into a plastic airbox. Seal is essential, however they’ll additionally chew out all of the plastic, particularly once you’re servicing the air filter frequently.

Keep in mind to slip the gasoline tank again into these two grommets, now we’ve obtained to reconnect all these pipes and connections. That’s the gasoline pump connector (pictured proper).

Plug the gasoline line again in and pop the pink lock again into place. Additionally push the gasoline pump connector again in.

DNA Air Filter fitment - Ninja 400

Now plug each these rubber pipes again into the tank and exchange the wire hose clamp

To attach each these pipes up on the other aspect of the tank, use your needle nostril pliers to run them again up, and tighten them. At this stage I’d advocate beginning the bike up to ensure the gasoline pump, gasoline line and breather pipe are correctly hooked up, as placing the whole lot again collectively to understand the gasoline pump connector didn’t fairly click on into place, or the gasoline line wasn’t fairly related can be fairly the effort.

Now get these bolts again in on the rear of the tank, underneath the rider seat. When you’ve received the tank bag mount, make sure that it’s correctly hooked up.

Simply repeat all of the early steps in reverse. Get these bolts connecting the fairings to the tank in place, and the push-pins. Tighten as the subsequent step of changing the beneath tank panel will take away entry. Now substitute the beneath tank panel, remembering it wants a agency hand to push again into the rubber mounting grommets. Then add the bolts down on the rider seat and up the highest. Additionally double examine the tank mounting bolts now, then add the rider seat, following by the pillion seat. And…. you’re sorted.

Our Project Ninja 400 fitted with the DNA airfilter!

Our Venture Ninja 400 fitted with the DNA airfilter!

And of course a DNA sticker to boot!

And naturally a DNA sticker as well!

All good motorbike outlets inventory DNA Efficiency air filters, so go seize one at the moment! Or for extra info take a look at the Kenma Australia web site:

You’ll additionally observe we’ve received a Ventura rack system fitted (EVO-22 and Euro-Rally), Oggy Knobbs, and the real Kawasaki seat cowl and Tank Bag.

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