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
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Other materials:

Transmission Shaft Disassembly
Remove the transmission shafts (see Transmission Shaft Removal). Remove the circlips, and then disassemble the transmission shafts. Special Tool - Outside Circlip Pliers: 57001-144 The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral fin ...

Drive Chain
The drive chain slack and lubrication must be checked each day before riding the motorcycle and must be maintained in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the chain becomes badly worn or maladjusted - either too loose or too tight - the c ...

Subthrottle Sensor Output Voltage Inspection
Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection, note the following. Disconnect the subthrottle sensor connector and connect the setting adapter [A] between these connectors. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538 ...