Kawasaki Ninja Service Manual: Piston Ring Thickness Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / Piston Ring Thickness Inspection

Measure the piston ring thickness.

Use the micrometer to measure at several points around the ring.

Piston Ring Thickness Standard:

Top [A] 0.77 0.79 mm (0.0303
0.0311 in.)

Second [B] 0.78 0.79 mm
(0.0307 0.0311 in.)

Service Limit:

Top 0.70 mm (0.0276 in.)

Second 0.71 mm (0.0280 in.)

Piston Ring Thickness Inspection

If any of the measurements is less than the service limit on either of the rings, replace all the rings.

NOTE

When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston.

Piston Ring Groove Width Inspection

Measure the piston ring groove width. Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A] 0.82 0.84 mm (0.0323 0.0331 in.) Second [B] 0.8 ...

Piston Ring End Gap Inspection

Place the piston ring [A] inside the cylinder (upper crankcase), using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. ...

Other materials:

Front Fork Removal (Each Fork Leg)
Loosen the front fork top plug [A] beforehand if the fork leg is to be disassembled. Special Tool - Top Plug Wrench (45 mm) [B]: 57001-1741 NOTE Loosen the top plug after loosening the handlebar clamp bolt [C] and upper front fork clamp bolt [D]. Remove: Upper Fairing Assembly (see Up ...

Lower Crankcase Assembly
Install the ball bearing [A] and the oil level inspection window [B] until they are bottomed Apply soap and water solution to the oil level inspection window before installation. Install the new circlip [C]. Apply a non-permanent locking agent to the oil passage plug [D]. Tighten: ...

Jump starting
If your motorcycle battery is “run down”, it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. DANGER Battery acid generates hydrogen gas which is flammable and explosive under certain conditions. It i ...