Kawasaki Ninja Service Manual: Piston Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / 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 disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the expander and one below it.

Spread the rail with your thumbs, but only enough to fit the rail over the piston.

Release the rail into the bottom piston ring groove.

NOTE

The oil ring rails have no “top” or “bottom”.

Piston Installation

Apply molybdenum disulfide oil solution to the piston rings.

NOTE

Do not mix up the top and second ring.

Install the top ring [A] so that the “1T” mark [B] faces up.
Install the second ring [C] so that the “T2” mark [D] faces up.

Piston Installation

Apply molybdenum disulfide oil solution to the piston pin and piston journal.

NOTE

If a new piston is used, use new piston rings.

Piston Installation

Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole.

When installing the piston pin snap ring, compress it only enough to install it and no more.

NOTICE

Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 40° of angle from the
opening of the top ring.

Top Ring [A] Second Ring [B] Oil Ring Steel Rails [C] Oil Ring Expander [D] Hollow [E] 30 40° [F]

Piston Installation

Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt.
Install the piston with itsmarking hollow [A] facing exhaust side.
Using the piston ring compressor assembly [B] to install the piston from the cylinder head side.

Special Tools - Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67

79:
57001-1097

Piston Installation

Install: Crankshaft (see Crankshaft Installation) Connecting Rod Big End Caps (see Connecting Rod Installation)

Piston Removal

Remove: Crankshaft (see Crankshaft Removal) Remove the piston together with the connecting rod to the cylinder head side. NOTICE Discard the connecting rod bolts and nuts. To prevent dam ...

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]. ...

Other materials:

Special Tools
Bearing Puller: 57001-135 Head Pipe Outer Race Press Shaft: 57001-1075 Steering Stem Nut Wrench: 57001-1100 Bearing Driver Set: 57001-1129 Steering Stem Bearing Driver, 42.5: 57001-1344 Steering Stem Bearing Driver Adapter, 41.5: 57001-1345 Head Pipe Outer Race Driver, 55: 57001- ...

Exploded View
CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. HG: Apply high-temperature grease. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. R: Replacement Parts S: Follow the specified tightening sequence. Specifications Special ...

Check 2-2: Fuel Level Warning Inspection
Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Connect the resistor(s) [A] (about 50 to 100 Ω) between the fuel pump connector terminal [B] of the main harness side and the battery negative (–) terminal [C] as shown. Turn the ignition switch ...