Kawasaki Ninja Service Manual: Piston Wear Inspection

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:

Fuel Tank and Cap Inspection
Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank and drain it ...

Immobilizer System (Equipped Models)
This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ECU. If the code does notmatch, ignition system, injectors, subthrottle valve actuator an ...

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] 0.82 0.84 mm (0.0323 0.0331 in.) Service Limit: 0.92 mm (0.036 in.) Second 0.92 mm (0.036 in.) ...