Kawasaki Ninja Service Manual: Camshaft, Camshaft Cap Wear Inspection

Kawasaki Ninja Service Manual / Engine Top End / Camshaft, Camshaft Chain / Camshaft, Camshaft Cap Wear Inspection

Remove the camshaft caps (see Camshaft Removal).
Cut the strips of plastigage (press gauge) to journal width.

Place a strip on each journal parallel to the camshaft installed in the correct position.
Tighten the camshaft cap bolts and upper camshaft chain guide bolts to the specified torque (see Camshaft Installation).

Camshaft, Camshaft Cap Wear Inspection

NOTE

Do not turn the camshaft when the plastigage is between the journal and camshaft cap.

Remove the camshaft cap again, measure each clearance between the camshaft journal and the camshaft cap using plastigage [A].

Camshaft Journal/Camshaft Cap Clearance Standard: 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Service Limit: 0.17 mm (0.0067 in.)

If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter Standard: 23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.) Service Limit: 23.91 mm (0.9413 in.)

If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

If the clearance still remains out of the service limit, replace the cylinder head unit.

Camshaft Installation

NOTE The exhaust camshaft has a 1001 EX mark [A] and the intake camshaft has a 3154 IN mark [B]. Be careful not to mix up these shafts. Install the camshaft sprockets as shown in the figure ...

Camshaft Runout Inspection

Remove the camshafts (see Camshaft Removal). Set the camshaft in a camshaft alignment jig or on V blocks. Measure the runout with a dial gauge at the specified place as shown in the figure. ...

Other materials:

Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
Remove the connecting rod big end (see Connecting Rod Removal). Cut strips of plastigage to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct position. Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod I ...

Fuse Box Fuse Removal
Remove the left upper inner fairing (see Upper Inner Fairing Removal in the Frame chapter). Unlock the hook [A] to take off the fuse box 1 [B]. Unlock the hook [C] to lift up the lid. Pull the fuses [A] straight out of the fuse box 1 with needle nose pliers. Fuse Box 2 ...

Battery Removal
Turn off the ignition switch. Remove the front seat (see Front Seat Removal in the Frame chapter). Slide the red cap [A]. Disconnect the negative (–) cable [B] and then positive (+) cable [C]. NOTICE Be sure to disconnect the negative (–) cable first. Remove the band [D] ...