Kawasaki Ninja Service Manual: Piston Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / 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 limit, replace the piston.

Piston Wear Inspection

Piston Diameter

Standard: 75.959 75.974 mm
(2.9905 2.9911 in.)
Service Limit: 75.81 mm (2.985 in.)

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]. ...

Piston Ring, Piston Ring Groove Wear Inspection

Check for uneven groove wear by inspecting the ring seating. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the pist ...

Other materials:

Water Temperature Sensor Resistance Inspection
Refer to the Water Temperature Sensor Inspection in the Electrical System chapter. If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter). Water Temperature Sensor Circuit 1. ECU 2. Water T ...

Crankshaft Sensor Installation
Apply a non-permanent locking agent to the crankshaft sensor bolts [A]. Tighten: Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cl ...

Shift Pedal Removal
Remove: Shift Lever Bolt [A] Front Footpeg Bracket Bolts [B] If the tie-rod [C] is to be removed from the shift pedal and the shift lever, loosen the tie-rod locknuts [D]. The front tie-rod locknut is left-hand thread. Remove: Shift Pedal Mounting Bolt [A] ...