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:

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Remove the intake air temperature sensor (see Intake Air Temperature Sensor Removal). Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. Suspend a thermometer [B] with the heat-sensitive portion [C] located in almost the same depth with ...

Meter Unit Removal/Installation
Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter) Remove the bolt [A] (other than US, CA and CALmodels). Slide back the dust cover and disconnect the meter unit connector [B]. Remove: Bolts [A] Nut [B] (other than US, CA and CAL mode ...

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S-KTRC is an intelligent system that calculates the slip level of the rear wheel (wheelspin) and is suitable for sports riding conditions. S-KTRC is designed to function on public roads. Acceleration may be delayed under certain circumstances depending on road conditions. S-KTRC cannot resp ...