Kawasaki Ninja Service Manual: Cylinder Compression Measurement

Kawasaki Ninja Service Manual / Engine Top End / Cylinder Head / Cylinder Compression Measurement

NOTE

Use the battery which is fully charged.

Warm up the engine thoroughly.
Stop the engine.
Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter).
Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole.
Using the startermotor, turn the engine over with the throttle fully open until the compression gauge stops rising; the compression is the highest reading obtainable.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221 Compression Gauge Adapter, M10 × 1.0: 57001-1601 L-Shape Hose [C]: 57001-1606

Cylinder Compression Measurement

Cylinder Compression Usable Range: 1 099 1 668 kPa (11.2
17.0 kgf/cm²,
159 242 psi) at 320 r/min (rpm)

Repeat the measurement for the other cylinders.
Install the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter).

The following table should be consulted if the obtainable compression reading is not within the usable range.

Problem	Diagnosis	Remedy (Action)
Cylinder compression is higher than usable range	Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke).	Remove the carbon deposits and replace damaged parts if necessary.
Cylinder compression is higher than usable range	Incorrect cylinder head gasket thickness	Replace the gasket with a standard part.
Cylinder compression is lower than usable range	Gas leakage around cylinder head	Replace damaged gasket and check cylinder head warp
	Bad condition of valve seating	Repair if necessary.
	Incorrect valve clearance	Adjust the valve clearance.
	Incorrect piston/cylinder clearance	Replace the piston and/or cylinder.
	Piston seizure	Inspect the cylinder and replace/repair the cylinder and/or piston as necessary.
	Bad condition of piston ring and/or piston ring grooves	Replace the piston and/or the piston rings.

Cylinder Head Removal

Remove: Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Exhaust Pipe (see Exhaust Pipe Removal) Camshafts (see Camshaft Removal) Heat Insulation Plate [A] (see E ...

Other materials:

Coolant Level Inspection
Situate the motorcycle so that it is perpendicular to the ground. Check the coolant level through the coolant level gauge on the reserve tank located to the left of the engine. The coolant level should be between the “F” (Full) and “L” (Low) level lines. A. Reserve Ta ...

Spring Plate Free Play Measurement
Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spongy” or pulsate when pulled. Hold an extra drive shaft in a vise and install the following c ...

Thermostat Installation
Replace the O-rings [A] with new ones, and apply grease to them. Assemble: O-rings Thermostat Housing [B] Thermostat [C] Thermostat Cap [D] Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top. Tighten: Torque - Thermostat Cap Bolts: 5.9 N ...