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:

Throttle Body Assy Assembly
Before assembling, blow away dirt or dust from the throttle body and delivery pipe assy by applying compressed air. Replace the O-rings [A] of the joint pipe [B] with new ones. Apply engine oil to the new O-rings, and insert it to the delivery pipes [C]. Insert the joint pipe so th ...

KIBS Hydraulic Unit Terminal Names
1. Ground: BK 2. CAN Communication Line (High): GY/BL 3. Front Wheel Rotation Sensor Signal Input: Y 4. Power Supply: BR/W 5. KIBS Kawasaki Self-Daignosis System Terminal: P 6. Front and Rear Brake Light Switch Signal: BL/R 7. Unused 8. Front Wheel Rotation Sensor Signal Output: G/Y 9. P ...

Rear Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature. Check to see that the caliper holder shafts ar ...