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:

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 ...

What if I am not Satisfied With My Warranty Service?
If you aren’t satisfied with your dealership’s repair work or operations, it is best to discuss the situation with the appropriate dealership manager. If you have already done this, then contact the dealership’s owner or general manager to request a review of the issue. If you are un ...

Fluid Level Inspection
With the brake fluid reservoirs held horizontal, the brake fluid level must be kept between the upper and lower level lines. A. Front Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line If th ...