Kawasaki Ninja Service Manual: Valve-to-Guide Clearance Measurement (Wobble Method)

Kawasaki Ninja Service Manual / Engine Top End / Valves / Valve-to-Guide Clearance Measurement (Wobble Method)

If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below.

Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
Move the stem back and forth [C] to measure valve/valve guide clearance.
Repeat the measurement in a direction at a right angle to the first.

If the reading exceeds the service limit, replace the guide.

Valve-to-Guide Clearance Measurement (Wobble Method)

NOTE

The reading is not actual valve/valve guide clearance because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method) Standard:

Exhaust 0.03 0.12 mm (0.0012
0.0047 in.)

Intake 0.03 0.13 mm (0.0012
0.0051 in.)

Service Limit:

Exhaust 0.34 mm (0.013 in.)

Intake 0.36 mm (0.014 in.)

Valve Guide Installation

Apply engine oil to the valve guide outer surface before installation. Heat the area around the valve guide hole to about 120 150°C (248 302°F). NOTICE Do not heat the cylinder head ...

Valve Seat Inspection

Remove the valve (see Valve Removal). Check the valve seating surface [A] between the valve [B] and valve seat [C]. Measure the outside diameter [D] of the seating pattern on the valve seat ...

Other materials:

Fuel Pump Operating Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove: Fuel Tank Bolts (see Fuel Tank Removal) Fuel Tank Bracket Bolts (see Fuel Tank Removal) Disconnect the fuel pump lead connector and connect the harness adapter [A] between these connectors as shown i ...

Spring Preload Adjustment
Remove the rear shock absorber from the frame (see Rear Shock Absorber Removal). Loosen the locknut and turn out the adjusting nut to free the spring. Special Tools - Hook Wrench T=3.2 R37: 57001-1539 Hook Wrench R=35: 57001-1580 To adjust the spring preload, turn in the adjusting n ...

Swingarm Installation
Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Apply a non-permanent locking agent to the threads of the chain guide bolt [B]. Apply plenty of grease to the lip of the oil seals [A]. Be sure to install the oil seals ...