Kawasaki Ninja Service Manual: Camshaft, Camshaft Cap Wear Inspection

Kawasaki Ninja Service Manual / Engine Top End / Camshaft, Camshaft Chain / Camshaft, Camshaft Cap Wear Inspection

Camshaft, Camshaft Cap Wear Inspection


Do not turn the camshaft when the plastigage is between the journal and camshaft cap.

Camshaft Journal/Camshaft Cap Clearance Standard: 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Service Limit: 0.17 mm (0.0067 in.)

If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter Standard: 23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.) Service Limit: 23.91 mm (0.9413 in.)

If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

If the clearance still remains out of the service limit, replace the cylinder head unit.

Camshaft Installation
NOTE The exhaust camshaft has a 1001 EX mark [A] and the intake camshaft has a 3154 IN mark [B]. Be careful not to mix up these shafts. Install the camshaft sprockets as shown in the figure ...

Camshaft Runout Inspection
Remove the camshafts (see Camshaft Removal). Set the camshaft in a camshaft alignment jig or on V blocks. Measure the runout with a dial gauge at the specified place as shown in the figure. ...

Other materials:

Troubleshooting Guide
NOTE Refer to the Fuel System chapter for most of DFI trouble shooting guide. This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doe ...

Fuel Tank
The following octane rating gasoline is recommended for the fuel tank. Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. A. Tank Cap B. Fuel Tank C. Top Level D. Filler Neck WARNINGGasoline is extremely flammable an ...

Battery Installation
Place the battery in the battery case. Connect the (+) cable to the (+) terminal, and then connect the (–) cable to the (–) terminal. NOTICE Installing the (–) cable to the (+) terminal of the battery or the (+) cable to the (–) terminal of the battery can seriously damaged ...