Kawasaki Ninja Service Manual: Crankshaft Main Bearing Insert/Journal Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankshaft and Connecting Rods / Crankshaft Main Bearing Insert/Journal Wear Inspection

Crankshaft Main Bearing Insert/Journal Wear Inspection


NOTE

Split the crankcase again, measure each clearance between the bearing insert and journal [B] using plastigage (press gauge).

Crankshaft Main Bearing Insert/Journal Clearance

Standard: 0.010 0.034 mm
(0.0004 0.0013 in.)


Service Limit: 0.06 mm (0.0024 in.)

If the clearance is within the standard, no bearing replacement is required.

If the clearance is between 0.035 mm (0.0014 in.) and the service limit (0.06 mm, 0.0024 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal clearance with the plastigage. The clearancemay exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.

If the clearance exceeds the service limit, measure the diameter of the crankshaft main journal.

Crankshaft Main Bearing Insert/Journal Wear Inspection


Crankshaft Main Journal Diameter

Standard: 34.984 35.000 mm
(1.3773 1.3780 in.)


Service Limit: 34.96 mm (1.3764 in.)

If any journal has worn past the service limit, replace the crankshaft with a new one.

If themeasured journal diameters [C] are not less than the service limit, but do not coincide with the original diameter markings [D] on the crankshaft, make new marks on it.

Crankshaft Main Journal Diameter Marks

None 34.984 34.992 mm (1.3773
1.3776 in.)


1 34.993 35.000 mm (1.3777
1.3780 in.)


Crankshaft Main Bearing Insert/Journal Wear Inspection


: Crankshaft Main Journal
Diameter Marks (“1” or No Mark)

Crankshaft Main Bearing Insert/Journal Wear Inspection


NOTE

The mark already on the upper crankcase half should almost coincide with the measurement.

Crankcase Main Bearing Inside Diameter Marks

38.000 38.008 mm (1.4961
1.4964 in.)


None 38.009 38.016 mm (1.4964
1.4967 in.)


Crankshaft Main Bearing Insert/Journal Wear Inspection


Crankshaft Main Bearing Insert/Journal Wear Inspection


*: The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.

Crankshaft Runout Inspection
Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.03 mm (0.0012 in.) or less Service Limit: TIR 0.08 mm ( ...

Pistons
...

Other materials:

Catalytic Converter
This motorcycle is equipped with a catalytic converter in the exhaust system. The converter reacts with carbonmonoxide, hydrocarbons and nitrogen oxides to convert them into carbon dioxide, water, nitrogen and oxygen resulting in much cleaner exhaust gases to be discharged into the atmosphe ...

Crankshaft Sensor Peak Voltage Inspection
Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter. If the reading is within the standard, remove the ECU and check the wiring for continuity between harness connectors. Special Tool - Hand Tester: 57001-1394 Disconnect the ECU and sensor connector ...

Transmission Assy Installation
Assemble the transmission assy (see Transmission Assy Assembly). Be sure that the dowel pins are in position. Install the transmission assy on the crankcase. Tighten: Torque - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) Install: Shift Shaft (see External Shift Mechani ...