Kawasaki Ninja Service Manual: Cylinder (Upper Crankcase) Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / 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].
Tighten the cylinder head bolts (see Cylinder Head Installation in the Engine Top End chapter).
Put the crankcase upside down.

Cylinder (Upper Crankcase) Wear Inspection

Since there is a difference in cylinder wear (upper crankcase) in different directions, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) as shown in the figure.

If any of the cylinder inside diameter measurements exceeds the service limit, replace the crankcase.

10 mm (0.39 in.) [A] 60 mm (2.36 in.) [B]

Cylinder (Upper Crankcase) Inside Diameter

Standard: 75.994 76.006 mm
(2.9919 2.9924 in.)

Service Limit: 76.09 mm (2.996 in.)

Cylinder (Upper Crankcase) Wear Inspection

Piston Installation

Apply molybdenum disulfide oil solution to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together Applymolybdenum disu ...

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 ...

Other materials:

Fuel Injector Fuel Line Inspection
Remove: Fuel Tank (see Fuel Tank Removal) Air Cleaner Housing (see Air Cleaner Housing Removal) Disconnect: Primary and Secondary Fuel Hoses (see Fuel Hose Replacement in the Periodic Maintenance chapter) Do not remove the nozzle assy from the air cleaner housing. Be sure to pla ...

Special Tools
Bearing Puller: 57001-135 Head Pipe Outer Race Press Shaft: 57001-1075 Steering Stem Nut Wrench: 57001-1100 Bearing Driver Set: 57001-1129 Steering Stem Bearing Driver, 42.5: 57001-1344 Steering Stem Bearing Driver Adapter, 41.5: 57001-1345 Head Pipe Outer Race Driver, 55: 57001- ...

Engine Sprocket Removal
Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Flatten out the bended washer [A]. Remove the engine sprocket nut [B] and washer. NOTE When loosening the engine sprocket nut, hold the rear brake on. Raise the rear wheel off the ground with the stand. ...