Kawasaki Ninja Service Manual: Camshaft, Camshaft Cap Wear Inspection

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

Camshaft, Camshaft Cap Wear Inspection


NOTE

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

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:

Stick Coil Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the ECU (see ECU Removal in the Fuel System (DFI) chapter). Do not disconnect the ECU connectors. Connect a digital meter [A] to the connector [B] with the needle adapter set. Special Tool - N ...

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 ...

Balance Inspection
Remove the front and rear wheels (see Front/Rear Wheel Removal). Support the wheel so that it can be spun freely. Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops. Repeat this procedure several times. If the wheel stops of its own accord in various positi ...