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:

Steering Stem Bearing Lubrication
Remove the steering stem (see Stem, Stem Bearing Removal in the Steering chapter). Using a high flash-point solvent, wash the upper and lower ball bearings [A] in the cages. Wipe the upper and lower outer races which are press -fitted into the head pipe to clean off grease and dirt. V ...

Oil Pump Drive Gear Shaft Installation
Apply molybdenum disulfide grease [A] to the oil pump drive gear shaft. Apply molybdenum disulfide oil solution to the followings. Transmission Case [B] Crankcase [C] Install the oil pump drive gear shaft and washer [D] as shown in the figure. Install the new circlip [E] into the ...

KIBS Servicing Precautions
There are a number of important precautions that should be followed servicing the KIBS. This KIBS is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. Do not reverse the battery cable connec ...