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:

Meter instruments
Upper Button Lower Button Tachometer (with Shift-Up Indicator) Red Zone Ambient Brightness Sensor Turn Signal Indicator Light Warning Indicator Light (Red) Neutral Indicator Light Multifunction Meter High Beam Indicator Light Warning Indicator Light (Yellow) Fuel ...

Seat Cover Installation
Installation is the reverse of removal. Note the following. When installing the pad [A], install it along the corner [B] as shown in the figure. When installing the pad [C], align the ends [D], along the corner [E], and wrap [F] the upper edge of the seat cover. Install the damper [A] ...

Intake Air Pressure Sensor #2 Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Disconnect the intake air pressure sensor #2 connector and connect the measuring adapter [A] between these con ...