Kawasaki Ninja Service Manual: Piston Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Pistons / 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 limit, replace the piston.

Piston Wear Inspection

Piston Diameter

Standard: 75.959 75.974 mm
(2.9905 2.9911 in.)
Service Limit: 75.81 mm (2.985 in.)

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]. ...

Piston Ring, Piston Ring Groove Wear Inspection

Check for uneven groove wear by inspecting the ring seating. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the pist ...

Other materials:

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). ...

Cylinder Compression Measurement
NOTE Use the battery which is fully charged. Warm up the engine thoroughly. Stop the engine. Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole. Using the startermo ...

Warning/Indicator Lights
: When the transmission is in neutral, the neutral indicator light goes on. : When the headlight is on high beam, the high beam indicator light goes on. : When the turn signal switch is pushed to the left or right, the turn signal indicator light blinks. ...