Kawasaki Ninja Service Manual: Piston Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / 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 limit, replace the piston.

Piston Wear Inspection

Piston Diameter

Standard: 75.959 75.974 mm
(2.9905 2.9911 in.)
Service Limit: 75.81 mm (2.985 in.)

Cylinder (Upper Crankcase) Wear Inspection

Split the crankcase (see Crankcase Splitting). Remove the pistons (see Piston Removal). Assemble the cylinder (upper crankcase) [A], the cylinder head [B] and the cylinder head gasket [C]. ...

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 pist ...

Other materials:

Drive Chain Removal/Installation
NOTE Since the drive chain is installed through the swingarm, The chain can not be removed other than by cutting it. Prepare the new link pin, link plate, grease seals, and tools for rejoining the chain. Remove: Bolts [A] Front Footpeg Bracket [B] Remove: Bolts [A] Chain Cover [B] ...

Clutch Cover Assembly
Replace the needle bearings and oil seal with new ones. NOTE Install the needle bearings so that the manufacture’s mark face out. Install the needle bearings [A] and oil seal [B] position as shown in the figure. Press the upper and lower bearings so that the bearing surface [ ...

KIBS Equipped Models
1. Clutch Cable 2. Vacuum Hose (Equipped Models) 3. Left Switch Housing Lead 4. Main Harness 5. Front Brake Hose 6. Throttle Cables 7. Right Switch Housing Lead 8. Bracket (Hold the brake pipes.) 9. Run the meter lead to outside of the meter bracket. 10. Run the vacuum hoses to inside o ...