Kawasaki Ninja Service Manual: Piston Ring, Piston Ring Groove Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / Piston Ring, Piston Ring Groove Wear Inspection

The rings should fit perfectly parallel to groove surfaces.

If not, replace the piston and all the piston rings.

Piston Ring, Piston Ring Groove Wear Inspection


Piston Ring/Groove Clearance Standard:

Top 0.03 0.07 mm (0.0012
0.0028 in.)


Second 0.03 0.06 mm (0.0012
0.0024 in.)


Service Limit:

Top 0.17 mm (0.0067 in.)

Second 0.16 mm (0.0063 in.)

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 ...

Piston Ring Groove Width Inspection
Measure the piston ring groove width. Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A] 0.82 0.84 mm (0.0323 0.0331 in.) Second [B] 0.8 ...

Other materials:

Exhaust Butterfly Valve Cable Installation
Confirm whether pulley [A] is an angle shown in the figure. 41.7° ±7° [B] This position is original position of the pulley. NOTE Correct the position electrically after confirming the use is discontinued and there is no damage when differing from the angle of shown in the figure. ...

Oil Pressure Relief Valve Inspection
Remove the oil pressure relief valve (see Oil Pressure Relief Valve Removal). Check to see if the valve [A] slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE Inspect the valve in its assembled stat ...

Fuel Hose Replacement
Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). WARNINGFuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fue ...