Air Filter Service - - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 1 (permalink) Old 5-5-2019, 10:48 PM Thread Starter
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Join Date: Sep 2016
Location: On the road, currently: Socal
Posts: 108
Air Filter Service

Servicing the air filter is an important maintenance task, inspect/clean in 7500 mile intervals and replace the filter after 5 cleanings. This should be done at higher frequencies when riding in dusty/dirty environments. Our motors depend on a vacuum from the air box to run correctly, if an air filter element is clogged or worse yet non existent, problems will occur. This task can be completed with the factory supplied tools under the seat, but higher quality tools will make it safer and easier to complete.

*Before going any further, if you have not read the Seat, Tank, and Fairing removal thread, go check that out, as we will be using some of those steps in this process.

You are responsible to take precautions to avoid any damages that occur during removal. Work slowly and deliberately. Please enlist the help of a mechanically inclined friend, neighbor or relative if uncomfortable and doing this the first time. Utilizing resources such as this post, service manual, and other sources is highly advisable. Think ahead, tidy up before starting, assure an organized working environment. Determine safe, temporary storage spaces for your components in advance.

*Tools (in addition to anything needed from the Seat, Tank and Fairing removal thread)

#2 Phillips
10mm socket/wrench
12mm socket/wrench
Ratchet (if using socket)
Socket extension
Small Torque wrench (optional)
Air filter cleaning solution
Air filter oil
Nitrile work gloves (optional)
Safety glasses (optional)
Disposable respirator (optional)
Clean rags


Start with the bike on center stand, flat, solid, stable ground.

Following steps shown in the Seat, Tank, Fairing Removal Thread, remove the seat and tank as shown.

Remove the four 10mm mounting bolts holding the fuel tank bracket. An extension will make accessing the bolts easier.

Remove the four Phillips head screws holding the plastic air box cover.

Push wires aside and gently pull up plastic air box cover to reveal the air filter.

Pull up and away from the air box to separate the air filter. Use a clean, lint free towel to cover the housing, keeping dirt or other matter from entering. *Inspect the filter for any damage, warping and/or breakdown in the seal, if anything is damaged replace it.

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur

While the filter is out it is a good time to clean the air-box of any dirt or grime.

Clean the element in a well-ventilated area, and make sure there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvents to clean.

Once the filter is out spray it with your choice of air filter cleaner or follow the cleaning steps from the brand manufacturer (I have K&N, so I use their steps/materials to clean).

Dry the filter with light compressed air or by shaking it and air drying.

Make sure the filter is fully dry, then lightly apply oil according to manufacturer, if using OEM filter apply SE30 spec SAE30 oil to a clean rag, then dab the surface of the filter until evenly applied.

Follow the steps in reverse for reassembly. Bolts are hand tight as not to rattle loose, but if you need a torque wrench, general guidelines per the service manual are 5mm Dia. threads get 3.4 - 4.9 N-m and 6mm Dia. threads get 5.9 - 7.8 N-m.

You now have a clean air filter. Remember to follow the maintenance schedule and always clean at higher frequencies, if you ride in dusty/muddy or rainy conditions more often than not.

Happy wrenching!

She just wants to see the world

Last edited by ksurk; 5-5-2019 at 10:54 PM.
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