Kawasaki Ninja Service Manual: Camshaft, Camshaft Cap Wear Inspection

Kawasaki Ninja Service Manual / Engine Top End / Camshaft, Camshaft Chain / Camshaft, Camshaft Cap Wear Inspection

Remove the camshaft caps (see Camshaft Removal).
Cut the strips of plastigage (press gauge) to journal width.

Place a strip on each journal parallel to the camshaft installed in the correct position.
Tighten the camshaft cap bolts and upper camshaft chain guide bolts to the specified torque (see Camshaft Installation).

Camshaft, Camshaft Cap Wear Inspection

NOTE

Do not turn the camshaft when the plastigage is between the journal and camshaft cap.

Remove the camshaft cap again, measure each clearance between the camshaft journal and the camshaft cap using plastigage [A].

Camshaft Journal/Camshaft Cap Clearance Standard: 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Service Limit: 0.17 mm (0.0067 in.)

If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter Standard: 23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.) Service Limit: 23.91 mm (0.9413 in.)

If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

If the clearance still remains out of the service limit, replace the cylinder head unit.

Camshaft Installation

NOTE The exhaust camshaft has a 1001 EX mark [A] and the intake camshaft has a 3154 IN mark [B]. Be careful not to mix up these shafts. Install the camshaft sprockets as shown in the figure ...

Camshaft Runout Inspection

Remove the camshafts (see Camshaft Removal). Set the camshaft in a camshaft alignment jig or on V blocks. Measure the runout with a dial gauge at the specified place as shown in the figure. ...

Other materials:

Brake Fluid Change
NOTE The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. Level the brake fluid reservoir. Remove: Screw [A] Stopper [B] Front Brake Reservoir Cap [C] Diaphragm Plate Diaphragm Remove the rubb ...

Crankshaft Sensor Installation
Apply a non-permanent locking agent to the crankshaft sensor bolts [A]. Tighten: Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cl ...

Sprocket Wear Inspection
Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter). Worn Tooth (Engine Sprocket) [A] Worn Tooth (Rear ...