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:

Valve Clearance Inspection
NOTE Valve clearance must be checked and adjusted when the engine is cold (at room temperature). Remove: Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter) Turn t ...

Windshield
Windshield Removal Remove: Bolts [A] and Washers Windshield [B] Windshield Installation Be sure to install the wellnuts [A] and the washers. Tighten: Torque - Windshield Mounting Bolts: 1.2 N·m (0.12 kgf·m, 11 in·lb) ...

Valve Guide Installation
Apply engine oil to the valve guide outer surface before installation. Heat the area around the valve guide hole to about 120 150°C (248 302°F). NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil. Usin ...