Kawasaki Ninja Service Manual: Operating Procedures

Kawasaki Ninja Service Manual / Engine Top End / Valves / Valve Seat Repair / Operating Procedures

NOTICE

Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced.

If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range.

Widened Width [A] of engagement by machining with 45° cutter

Ground Volume [B] by 32° cutter 32° [C]

Correct Width [D]

Ground Volume [E] by 60° cutter 60° [F]

Operating Procedures


If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.

Original Seating Surface [B]

NOTE

If the outside diameter [A] of the seating surface is too large, make the 32° grind described below.

If the outside diameter of the seating surface is within the specified range, measure the seat width as described below.

Operating Procedures


To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide.

Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.

Operating Procedures


NOTICE

The 32° cutter removes material very quickly.

Check the seat outside diameter frequently to prevent overgrinding.

After making the 32° grind, return to the seat outside diameter measurement step above.

If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat outside diameter measurement step above.

If the seat width is too wide, make the 60° [A] grind described below.

If the seat width is within the specified range, lap the valve to the seat as described below.

To make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide.

Turn the holder, while pressing down lightly.

After making the 60° grind, return to the seat width measurement step above.

Correct Width [B]

Operating Procedures


NOTICE

Do not lap the valve to the valve seat, using the grinding compound. It will come off oxide film treated surface of the valve.

Operating Procedures


Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or ...

Throttle Body Assy Holder
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Other materials:

Meter instruments
Upper Button Lower Button Tachometer (with Shift-Up Indicator) Red Zone Ambient Brightness Sensor Turn Signal Indicator Light Warning Indicator Light (Red) Neutral Indicator Light Multifunction Meter High Beam Indicator Light Warning Indicator Light (Yellow) Fuel ...

Cylinder Head Cover Removal
Remove: Air Suction Valves (see Air Suction Valve Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Stick Coils (see Stick Coil Removal in the Electrical System chapter) Remove the clamps [A]. Turn up the front side of the heat insulation ...

Armature Inspection
Using the × 1 Ω hand tester range, measure the resistance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced. ...