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:

Valve Guide Removal
Remove: Valve (see Valve Removal) Oil Seal Spring Seat Heat the area around the valve guide to 120 150°C (248 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. NOTICE Do not heat the cylinder head with a torch. This ...

Water Pump Housing Disassembly
NOTICE Do not damage the hole wall of the water pump housing. Insert a bar [A] into the pump housing [B], and hammer evenly around the circumference of the mechanical seal bottom [C]. Take the oil seal [A] out of the housing [B] with a hook [C]. ...

Exhaust Butterfly Valve Actuator Sensor Resistance Inspection
Turn the ignition switch to OFF. Disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [A] (see Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection). Connect a digital meter [B] to the exhaust butterfly valve actuator sensor connector. Measur ...