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

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / Cylinder (Upper Crankcase) Wear Inspection

Cylinder (Upper Crankcase) Wear Inspection


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:

Intake Air Pressure Sensor #2 Output Voltage Inspection
Measure the output voltage at the intake air pressure sensor #2 in the same way as input voltage inspection, note the following. Disconnect the intake air pressure sensor #2 connector and connect the measuring adapter [A] between these connectors. [B] Main Harness [C] Intake Air Pressu ...

Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, n ...

Coolant Filling
Remove the bolts and quick rivets. Detach the tabs and remove the right fairing and cover. A. Bolts B. Quick Rivet C. Large Quick Rivet D. Tabs E. Right Fairing and Cover NOTE The right fairing and cover uses the quick rivets and large quick rivet. The large quick rivet ca ...