Kawasaki Ninja Service Manual: Valve Clearance Inspection

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Engine Top End / 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 the crankshaft, align the #1, 4 mark on the timing rotor with the crankcase timing mark.

TDC Mark [A] for #1, 4 Pistons Timing Mark [B] (Crankcase Halves Mating Surface)

Valve Clearance Inspection

Using a thickness gauge [A], measure the valve clearance between the cam and the valve lifter.

Valve Clearance

Standard: Exhaust 0.17 0.22 mm (0.0067
0.0087 in.)

Intake 0.15 0.22 mm (0.0059
0.0087 in.)

Valve Clearance Inspection

NOTE

Thickness gauge is horizontally inserted on the valve lifter.

Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G]

Valve Clearance Inspection

When positioning #1 piston TDC at the end of the compression stroke:

Intake Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A]

Valve Clearance Inspection

When positioning #4 piston TDC at the end of the compression stroke:

Intake Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders Measuring Valve [A]

Valve Clearance Inspection

If the valve clearance is not within the specified range, first record the clearance, and then adjust it.

Valve Clearance Adjustment

To change the valve clearance, remove the camshafts (see Camshaft Removal in the Engine Top End chapter) and valve lifters. Replace the shim with one of a different thickness. NOTE Ma ...

Other materials:

Air Cleaner Housing Assembly
Install the ducts to the air cleaner housing. Fit the projections [A] of the duct into the slits [B] on the air cleaner housing. Tighten the screws [A]. Torque - Air Cleaner Housing Duct Screws: 1.1 N·m (0.11 kgf·m, 10 in·lb) Install: Air Cleaner Gasket [A] Duct [B] ...

Oil Pressure Relief Valve Inspection
Remove the oil pressure relief valve (see Oil Pressure Relief Valve Removal). Check to see if the valve [A] slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE Inspect the valve in its assembled stat ...

Oil Pump Drive Gear Installation
Install is the reverse of removal. Note the following. First, engage the oil pump chain [A] to the gears, and then install the oil pump drive gear [B]. Turn the “OUT” mark [C] to outside. Apply a non-permanent locking agent to the oil pump drive chain guide bolt and the oil pump drive ...