Kawasaki Ninja Service Manual: Cylinder (Upper Crankcase) Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / 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].
Tighten the cylinder head bolts (see Cylinder Head Installation in the Engine Top End chapter).
Put the crankcase upside down.

Cylinder (Upper Crankcase) Wear Inspection

Since there is a difference in cylinder wear (upper crankcase) in different directions, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) as shown in the figure.

If any of the cylinder inside diameter measurements exceeds the service limit, replace the crankcase.

10 mm (0.39 in.) [A] 60 mm (2.36 in.) [B]

Cylinder (Upper Crankcase) Inside Diameter

Standard: 75.994 76.006 mm
(2.9919 2.9924 in.)

Service Limit: 76.09 mm (2.996 in.)

Cylinder (Upper Crankcase) Wear Inspection

Piston Installation

Apply molybdenum disulfide oil solution to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together Applymolybdenum disu ...

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 ...

Other materials:

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. If the outside diameter is too large or too small, repair the seat (see Valve Seat Repair). Val ...

Transmission Assy Assembly
Install the ball bearing [A] until it is bottomed. Turn the oil seal side to the bottom. Special Tool - Bearing Driver Set: 57001-1129 Install the bearing holder [B]. Turn the flat side to the bottom. Apply a non-permanent locking agent to the bearing holder bolts [C]. Tighten: ...

Clutch Removal
Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs (with Clutch Spring Holders) Clutch Spring Plate [B] Pusher [C] Remove: Friction Plates (10) [A] Steel Plates (9) [B] Spring [C] Spring Seat [D] Hold the sub clutch hub [A] ...