Kawasaki Ninja Service Manual: Piston Ring, Piston Ring Groove Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / Piston Ring, Piston Ring Groove Wear Inspection

The rings should fit perfectly parallel to groove surfaces.

If not, replace the piston and all the piston rings.

Piston Ring, Piston Ring Groove Wear Inspection


Piston Ring/Groove Clearance Standard:

Top 0.03 0.07 mm (0.0012
0.0028 in.)


Second 0.03 0.06 mm (0.0012
0.0024 in.)


Service Limit:

Top 0.17 mm (0.0067 in.)

Second 0.16 mm (0.0063 in.)

Piston Wear Inspection
Measure the outside diameter [A] of each piston 5 mm (0.20 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service ...

Piston Ring Groove Width Inspection
Measure the piston ring groove width. Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A] 0.82 0.84 mm (0.0323 0.0331 in.) Second [B] 0.8 ...

Other materials:

Subthrottle Valve Actuator Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Disconnect the subthrottle valve actuator connector and connect the measuring adapter [A] between these connectors as shown in the figure. Main Harness [B] Subthrottle Valve Actuator [C] Special Tool ...

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. ...

Brake Disc Wear Inspection
Measure the thickness of each disc [A] at the point where it has worn the most. If the disc has worn past the service limit, replace it. Measuring Area [B] Brake Disc Thickness Standard: Front 5.3 5.7 mm (0.21 0.22 in.) Rear 4.8 5.2 mm (0.19 0.20 in.) Service Limit: Front 5. ...