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:

Subthrottle Valve Actuator Inspection
NOTE Be sure the battery is fully charged. Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Turn the ignition switch to ON. Check to see that all the subthrottle valves [A] open and close smoothly. Turn the ignition switch to OFF. I ...

Turn Signal Switch
When the turn signal switch is pushed to the left ( ) or right ( ), the corresponding turn signals blink on and off. To stop blinking, push the switch in. Horn Button When the horn button is pushed, the horn sounds LAP/Passing Button When the LAP/passing button is pushed, the headlight hi ...

KIBS System Circuit
1. Ignition Switch 2. Front Wheel Rotation Sensor 3. Front Brake Light Switch 4. Joint Connector C 5. Joint Connector D 6. ECU 7. Rear Wheel Rotation Sensor 8. Rear Brake Light Switch 9. Battery 12 V 8.6 Ah 10. Main Fuse 30 A 11. KIBS Motor Relay Fuse 30 A 12. KIBS Solenoid Valve Rela ...