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

Check for uneven groove wear by inspecting the ring seating.

The rings should fit perfectly parallel to groove surfaces.

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

With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance.

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:

Battery Maintenance
It is the owner’s responsibility to keep the battery fully charged. Failure to do so can lead to battery failure and leave you stranded. If you are riding your vehicle infrequently, inspect the battery voltage weekly using a voltmeter. If it drops below 12.8 volts, the battery should be ...

Clutch Cover Installation
Using a cleaning fluid, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth. Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Liquid Gasket, TB1211F: 92104-000 ...

Cable Removal
Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Loosen the nuts [A], and slide the lower end of the clutch cable to give the cable plenty of play. Screw in the ...