Kawasaki Ninja Service Manual: Cylinder Compression Measurement

Kawasaki Ninja Service Manual / Engine Top End / Cylinder Head / Cylinder Compression Measurement

NOTE

Use the battery which is fully charged.

Warm up the engine thoroughly.
Stop the engine.
Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter).
Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole.
Using the startermotor, turn the engine over with the throttle fully open until the compression gauge stops rising; the compression is the highest reading obtainable.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221 Compression Gauge Adapter, M10 × 1.0: 57001-1601 L-Shape Hose [C]: 57001-1606

Cylinder Compression Measurement

Cylinder Compression Usable Range: 1 099 1 668 kPa (11.2
17.0 kgf/cm²,
159 242 psi) at 320 r/min (rpm)

Repeat the measurement for the other cylinders.
Install the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter).

The following table should be consulted if the obtainable compression reading is not within the usable range.

Problem	Diagnosis	Remedy (Action)
Cylinder compression is higher than usable range	Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke).	Remove the carbon deposits and replace damaged parts if necessary.
Cylinder compression is higher than usable range	Incorrect cylinder head gasket thickness	Replace the gasket with a standard part.
Cylinder compression is lower than usable range	Gas leakage around cylinder head	Replace damaged gasket and check cylinder head warp
	Bad condition of valve seating	Repair if necessary.
	Incorrect valve clearance	Adjust the valve clearance.
	Incorrect piston/cylinder clearance	Replace the piston and/or cylinder.
	Piston seizure	Inspect the cylinder and replace/repair the cylinder and/or piston as necessary.
	Bad condition of piston ring and/or piston ring grooves	Replace the piston and/or the piston rings.

Cylinder Head Removal

Remove: Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Exhaust Pipe (see Exhaust Pipe Removal) Camshafts (see Camshaft Removal) Heat Insulation Plate [A] (see E ...

Other materials:

External Shift Mechanism Inspection
Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration [B] are damaged, replace the shaft. If the spring [C] is damaged in any way, replace it. If the shift mechanism arm [D] is damaged in any way, replace the shaft. Check the s ...

Rear Shock Absorber Installation
Replace the rear shock absorber nuts and tie-rod nuts with new ones. Tighten: Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) When installing the rear shock absorber bracket [A], install it so that the recess side [B] ...

Clutch Removal
Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs (with Clutch Spring Holders) Clutch Spring Plate [B] Pusher [C] Remove: Friction Plates (10) [A] Steel Plates (9) [B] Spring [C] Spring Seat [D] Hold the sub clutch hub [A] ...