Kawasaki Ninja 300 / Ninja 300 ABS Motorcycle. Service Manual (2013)

5-12 ENGINE TOP END

Clean Air System

Air Suction Valve Removal

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)

•

Disconnect the hose [A] from the air suction valve cover
[B].

•

Remove:

Air Suction Valve Cover Bolts [C]
Air Suction Valve Cover [B]
Air Suction Valve

Air Suction Valve Installation

•

Install the air suction valve [A] so that its wider side [B] of
the reed valve case faces the front.

•

Tighten:

Torque - Air Suction Valve Cover Bolts : 9.8 N·m (1.0 kgf·m,

87 in·lb)

•

Install the removed parts (see appropriate chapters).

Air Suction Valve Inspection

•

Remove the air suction valve (see Air Suction Valve Re-
moval).

•

Visually inspect the reeds for cracks, folds, warps, heat
damage or other damage.
If there is any doubt as to the condition of the reeds [A],
replace the air suction valve as an assembly.

•

Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation from the
holder or heat damage.

•

If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.

•

If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high flash-point solvent.

NOTICE

Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.

Air Switching Valve Removal

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)

•

Remove the frame ground terminal bolt [A].

•

Disconnect the connectors [B].

•

Remove the hose [C] from the intake air pressure sensor.

•

Remove the hoses [C] from the air suction valve cover
and air cleaner housing fitting, and remove the air switch-
ing valve assembly [D].

ENGINE TOP END 5-13

Clean Air System

•

Remove the hoses from the air switching valve assembly.

•

Remove:

Intake Air Pressure Sensor [A]
Damper [B]
Air Switching Valve [C]

NOTICE

Never drop the air switching valve especially on
a hardsurface. Such a shock to the air switching
valve can damaged it.

Air Switching Valve Installation

•

Installation is the reverse of removal.

•

Run the lead and hoses correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).

•

Install the removed parts (see appropriate chapters).

Air Switching Valve Operation Test

•

Refer to the Air Suction System Damage Inspection in the
Periodic Maintenance chapter.

Air Switching Valve Unit Test

•

Refer to the Air Switching Valve Unit Test in the Electrical
System chapter.

Clean Air System Hose Inspection

•

Be certain that all the hoses are routed without being flat-
tened or kinked, and are connected correctly to the air
cleaner housing, air switching valve and air suction valve
cover.
If they are not, correct them. Replace them if they are
damaged.

5-14 ENGINE TOP END

Cylinder Head Cover

Cylinder Head Cover Removal

•

Remove:

Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Air Switching Valve (see Air Switching Valve Removal)
Air Suction Valve Cover (see Air Suction Valve Removal)
Stick Coils (see Stick Coil Removal in the Electrical Sys-
tem chapter)
Water Hose [A]
Bolts [B] and Bracket [C]

•

Remove:

Cylinder Head Cover Bolts [A]
Cylinder Head Cover [B]

Cylinder Head Cover Installation

•

Replace the head cover gasket with a new one.

•

Clean off any oil or dirt and apply liquid gasket [A] to the
head cover gasket as shown.

Sealant - Liquid Gasket, TB1216B: 92104-1064

•

Install the new head cover gasket.

•

Install:

Dowel Pins [A]
Plug Hole Gaskets [B]

5-16 ENGINE TOP END

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

NOTICE

This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below.
When removing the tensioner, do not take out the
mounting bolts only halfway.

Retightening the

mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in "Camshaft Chain Ten-
sioner Installation".
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing and damage the valves.

•

Remove:

Right Middle Fairing (see Middle Fairing Removal in the
Frame chapter)
Cap Bolt [A]
Mounting Bolts [B]
Camshaft Chain Tensioner [C]

Camshaft Chain Tensioner Installation

•

While compressing the push rod [A], turn it clockwise with
a suitable screwdriver until the rod stopped.

NOTICE

Do not turn the rod counterclockwise before in-
stalling the tensioner. This could detach the rod
and the tensioner cannot be reinstalled.

•

Replace the camshaft chain tensioner gasket with a new
one.

•

While holding the rod in position with a suitable push rod
holder plate [A] install the tensioner on the cylinder block.

3.5 mm (0.14 in.) [B]
7 mm (0.28 in.) [C]
12 mm (0.47 in.) [D]
8.5 mm (0.33 in.) [E]

5-18 ENGINE TOP END

Camshaft, Camshaft Chain

Camshaft Removal

•

Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Plugs [A] [B]

Special Tool - Filler Cap Driver: 57001-1454

•

Position the crankshaft at #2 piston TDC.

○

Using a wrench on the alternator rotor bolt, turn the crank-
shaft counterclockwise until the "2T" mark [A] on the al-
ternator rotor is aligned with the projection [B] in the in-
spection window on the alternator cover.

•

Remove:

Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Camshaft Cap Bolts [A]
Plates
Upper Chain Guide [B]
Camshaft Caps [C]
Camshafts [D]

○

Loosen the camshaft cap bolts gradually and evenly as
shown sequence [1

∼

12].

•

Stuff a clean cloth into the chain tunnel to keep any parts
from dropping into the crankcase.

•

Remove:

Camshaft Sprocket Bolts [A]
Camshaft Sprockets [B]

NOTICE

The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turn-
ing the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.

ENGINE TOP END 5-19

Camshaft, Camshaft Chain

Camshaft Installation

•

Install the camshaft sprockets as shown.

Intake Camshaft Sprocket [A]
Exhaust Camshaft Sprocket [B]

○

The exhaust camshaft has the groove [C].

•

Apply a non-permanent locking agent to the threads of
the camshaft sprocket bolts and tighten them.

Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11

ft·lb)

•

Apply molybdenum disulfide oil solution to all cam parts
and journals.
If a new camshaft is to be used, apply a thin coat of molyb-
denum disulfide grease to the cam surfaces.

NOTE

○

Be sure to operate from the engine left side.

•

Position the crankshaft at #2 piston TDC (see Camshaft
Removal).

NOTICE

•

Engage the camshaft chain [A] with the camshaft sprock-
ets.

•

Pull the tension side (exhaust side) of the chain taut to
install the chain on the sprockets.

○

Timing marks [B] align with the cylinder head upper sur-
face.

Exhaust Camshaft Sprocket [C]
Intake Camshaft Sprocket [D]

○

Count the camshaft chain link pins as shown to verify that
the sprocket are positioned correctly.

5-20 ENGINE TOP END

Camshaft, Camshaft Chain

•

Install the six dowel pins on the

marks [A].

•

Install the camshaft caps as shown, noting the “EX” [B]
and “IN” [C] marks.

NOTICE

The camshaft caps are machined with the cylinder
head. So, if a cap is installed in a wrong location,
the camshaft may seize because of improper oil
clearance in the bearings.

•

Install the plates on the camshaft caps.

○

The exhaust side plates [A] are longer than the intake side
plates [B].

•

Install the upper chain guide [A].

•

First tighten the all camshaft cap bolts evenly to seat the
camshaft in place, then tighten all bolts following the spec-
ified tightening sequence.

Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

Plates (EX) [B]
Plates (IN) [C]

•

Install the camshaft chain tensioner (see Camshaft Chain
Tensioner Installation).

•

Finally, inject [A] the engine oil into 8 places on the cylin-
der head as shown.

•

Install the cylinder head cover (see Cylinder Head Cover
Installation).

ENGINE TOP END 5-21

Camshaft, Camshaft Chain

Camshaft, Camshaft Cap Wear Inspection

•

Remove:

Upper Chain Guide (see Camshaft Removal)
Camshaft Caps (see Camshaft Removal)

•

Cut the strips of plastigauge to journal width. Place a strip
on each journal parallel to the camshaft installed in the
correct position.

•

Measure each clearance between the camshaft journal
and the camshaft cap using the plastigauge (press gauge)
[A].

•

Tighten the camshaft cap bolts (see Camshaft Installa-
tion).

NOTE

○

Do not turn the camshaft when the plastigauge is be-
tween the journal and camshaft cap.

Camshaft Journal, Camshaft Cap Clearance

Standard:

0.028

∼

0.071 mm (0.0011

∼

0.0028 in.)

Service Limit: 0.16 mm (0.0063 in.)

If any clearance exceeds the service limit, measure the
diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter

Standard:

23.950

∼

23.972 mm (0.9429

∼

0.9438 in.)

Service Limit: 23.92 mm (0.942 in.)

If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
If the clearance still remains out of the service limit, re-
place the cylinder head unit.

Camshaft Runout Inspection

•

Remove the camshafts (see Camshaft Removal).

•

Set the camshaft in a camshaft alignment jig or on V
blocks.

•

Measure the runout with a dial gauge at the specified
place as shown.
If the runout exceeds the service limit, replace the
camshaft.

Camshaft Runout

Standard:

TIR 0.02 mm (0.0008 in.) or less

Service Limit: TIR 0.1 mm (0.004 in.)

5-22 ENGINE TOP END

Camshaft, Camshaft Chain

Cam Wear Inspection

•

Remove the camshafts (see Camshaft Removal).

•

Measure the height [A] of each cam with a micrometer.
If the cams are worn down past the service limit, replace
the camshaft.

Cam Height

Standard:

Exhaust

32.843

∼

32.957 mm (1.2930

∼

1.2975 in.)

Intake

33.843

∼

33.957 mm (1.3324

∼

1.3369 in.)

Service Limit:

Exhaust

32.74 mm (1.289 in.)

Intake

33.74 mm (1.328 in.)

Camshaft Chain Removal

•

Split the crankcase (see Crankcase Splitting in the Crank-
shaft/Transmission chapter).

•

Remove the camshaft chain [A] from the crankshaft
sprocket.

ENGINE TOP END 5-23

Cylinder Head

Cylinder Compression Measurement

NOTE

○

Use the battery which is fully charged.

•

Warm up the engine thoroughly.

•

Stop the engine.

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Stick Coils (see Stick Coil Removal in the Electrical Sys-
tem chapter)
Spark Plugs (see Spark Plug Replacement in the Peri-
odic Maintenance chapter)

•

Attach the compression gauge [A] and adapter [B] firmly
into the spark plug hole.

•

Using the starter motor, turn the engine over with the throt-
tle fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221

Compression Gauge Adapter, M10 × 1.0:

57001-1317

Cylinder Compression

Usable Range: 1 120

∼

1 698 kPa (11.4

∼

17.3 kgf/cm²,

162

∼

246 psi) at 500 r/min (rpm)

•

Repeat the measurement for the other cylinder.

•

Install the spark plugs.

Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)

○

The following table should be consulted if the obtainable compression reading is not within the us-
able range.

Problem

Diagnosis

Remedy (Action)

Carbon accumulation on piston and in
combustion chamber possibly due to
damaged valve stem oil seal and/or
damaged piston oil rings (This may be
indicated by white exhaust smoke).

Remove the carbon deposits
and replace damaged parts if
necessary.

Cylinder compression
is higher than usable
range.

Incorrect cylinder head gasket
thickness

Replace the gasket with a standard
part.

Gas leakage around cylinder head

Replace damaged check gasket
and cylinder head warp.

Bad condition of valve seating

Repair if necessary.

Incorrect valve clearance

Adjust the valve clearance.

Incorrect piston/cylinder clearance

Replace the piston and/or cylinder.

Piston seizure

Inspect the cylinder and
replace/repair the cylinder and/or
piston as necessary.

Cylinder compression
is lower than usable
range.

Bad condition of piston ring and/or
piston ring grooves

Replace the piston and/or the
piston rings.

5-24 ENGINE TOP END

Cylinder Head

Cylinder Head Removal

•

Drain:

Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)

•

Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Camshafts (see Camshaft Removal)
Radiator (see Radiator and Radiator Fan Removal in the
Cooling System chapter)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Exhaust Pipe (see Exhaust Pipe Removal)
Water Pipe [A]
Dampers [B]
O-rings [C]

•

Remove:

Front Camshaft Chain Guide [A]

•

Remove the drain bolt [A] to drain the coolant from the
cylinder.

•

Remove the oil pipe banjo bolt [B].

•

Remove:

Upper Engine Mounting Bracket Nuts and Bolts [A] (Both
Sides)
Engine Mounting Bracket Nut and Bolt [B] (L = 210)
Engine Mounting Bracket Nut and Bolt [C] (L = 240)
Upper Engine Mounting Bracket [D] (Both Sides)
Engine Mounting Bracket [E]

ENGINE TOP END 5-25

Cylinder Head

•

Remove:

M6 Cylinder Head Bolt [A]
M8 Cylinder Head Bolts [B]
Cylinder Head

Cylinder Head Installation

NOTE

○

The camshaft cap is machined with the cylinder head,
so if a new cylinder head is installed, use the cap that
is supplied with the new head.

•

Replace the cylinder head gasket [A] with a new one.

•

Install the dowel pins [B] and cylinder head gasket.

•

Replace the cylinder head bolt washers with new ones.

•

Apply molybdenum disulfide oil solution to both sides [A]
of the cylinder head bolt washers [B] and the threads of
the head bolts [C].

•

Tighten the M8 cylinder head bolts following the tightening
sequence [1

∼

7].

146 mm (5.75 in.) [1

∼

115 mm (4.53 in.) [7]

Torque - Cylinder Head Bolts (M8, L = 146): 32 N·m (3.3

kgf·m, 24 ft·lb)

Cylinder Head Bolt (M8, L = 115): 32 N·m (3.3

kgf·m, 24 ft·lb)

•

Tighten the M6 cylinder head bolt [8].

Torque - Cylinder Head Bolt (M6): 12 N·m (1.2 kgf·m, 106

in·lb)

5-26 ENGINE TOP END

Cylinder Head

•

Install:

Front Camshaft Chain Guide [A]

•

Replace the O-ring [A] with a new one.

•

Apply grease to the O-ring.

•

Install the water pipe [B] and dampers [C] (see Cylinder
Head Cover Installation).

•

Install the removed parts (see appropriate chapters).

Cylinder Head Warp Inspection

•

Clean the cylinder head.

•

Lay a straightedge across the lower surface of the cylinder
head at several positions.

•

Use a thickness gauge [A] to measure the space between
the straightedge [B] and the head.

Cylinder Head Warp

Standard:

– – –

Service Limit: 0.05 mm (0.002 in.)

If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).

ENGINE TOP END 5-27

Valves

Valve Clearance Inspection

•

Refer to the Valve Clearance Inspection in the Periodic
Maintenance chapter.

Valve Clearance Adjustment

•

Refer to the Valve Clearance Adjustment in the Periodic
Maintenance chapter.

Valve Removal

•

Remove:

Cylinder Head (see Cylinder Head Removal)
Valve Lifter and Shim

○

Mark and record the valve lifter and shim locations so they
can be installed in their original positions.

•

Using the valve spring compressor assembly, remove the
valve.

Special Tools - Valve Spring Compressor Assembly [A]:

57001-241

Valve Spring Compressor Adapter, 16 [B]:

57001-1305

Valve Installation

•

Replace the oil seal with a new one.

•

Apply engine oil to the lip of the oil seal.

•

Apply a thin coat of molybdenum disulfide grease to the
valve stem before valve installation.

•

Install the spring so that the closed coil end faces down-
wards.

Valve Stem [A]
Spring Seat [B]
Valve Spring (Yellow-Green) [C]
Oil Seal [D]
Retainer [E]
Split Keepers [F]
Closed Coil End [G]

Valve Guide Removal

•

Remove:

Valve (see Valve Removal)
Oil Seal
Spring Seat

•

Heat the area around the valve guide to 120

∼

150°C (248

∼

302°F), and hammer lightly on the valve guide arbor [A]

to remove the guide from the top of the head.

NOTICE

Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.

Special Tool - Valve Guide Arbor, 4.5: 57001-1331

5-28 ENGINE TOP END

Valves

Valve Guide Installation

•

Apply engine oil to the valve guide outer surface before
installation.

•

Heat the area around the valve guide hole to about 120

∼

150°C (248

∼

302°F).

NOTICE

Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head and
heat the oil.

•

Using the valve guide driver [A] and washer [B], press
and insert the valve guide in until the washer surface [C]
touches the head surface [D].

15.3

∼

15.5 mm (0.60

∼

0.61 in.) [E]

Special Tools - Valve Guide Driver: 57001-1564

Washer: 57001-1720

•

Wait until the cylinder head cools down and then ream the
valve guide with the valve guide reamer [A] even if the old
guide is reused.

○

Turn the reamer in a clockwise direction until the reamer
turns freely in the guide. Never turn the reamer counter-
clockwise or it will be dulled.

○

Once the guides are reamed they must be cleaned thor-
oughly.

Special Tool - Valve Guide Reamer, 4.5: 57001-1333

Valve-to-Guide Clearance Measurement (Wobble

Method)

If a small bore gauge is not available, inspect the valve

guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.

•

Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.

•

Move the stem back and forth [C] to measure valve/valve
guide clearance.

•

Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the guide.

ENGINE TOP END 5-29

Valves

NOTE

○

The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)

Standard:

Exhaust

0.08

∼

0.15 mm (0.0031

∼

0.0059 in.)

Intake

0.03

∼

0.09 mm (0.0012

∼

0.0035 in.)

Service Limit:

Exhaust

0.33 mm (0.013 in.)

Intake

0.27 mm (0.011 in.)

Valve Seat Inspection

•

Remove the valve (see Valve Removal).

•

Check the valve seating surface [A] between the valve [B]
and valve seat [C].

○

Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Seat Repair).

Valve Seating Surface Outside Diameter

Standard:

Exhaust 19.3

∼

19.5 mm (0.7598

∼

0.7677 in.)

Intake

23.1

∼

24.1 mm (0.9094

∼

0.9488 in.)

○

Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.

Good [F]

If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).

Valve Seating Surface Width

Standard:

Exhaust

0.5

∼

1.0 mm (0.0197

∼

0.0394 in.)

Intake

0.5

∼

1.0 mm (0.0197

∼

0.0394 in.)

Valve Seat Repair

•

Repair the valve seat with the valve seat cutters [A].

Special Tools - Valve Seat Cutter Holder Bar [B]: 57001

-1128

Valve Seat Cutter Holder,

4.5 [C]: 57001

-1330

[For Exhaust Valve Seat]

Valve Seat Cutter, 45° - 24.5: 57001-1113
Valve Seat Cutter, 32° - 22: 57001-1206
Valve Seat Cutter, 67.5° - 22: 57001-1207

[For Intake Valve Seat]

Valve Seat Cutter, 45° - 24.5: 57001-1113
Valve Seat Cutter, 32° - 25: 57001-1118
Valve Seat Cutter, 67.5° - 22: 57001-1207

If the manufacturer’s instructions are not available, use
the following procedure.

5-30 ENGINE TOP END

Valves

Seat Cutter Operation Care

1. This valve seat cutter is developed to grind the valve for

repair. Therefore the cutter must not be used for other
purposes than seat repair.

2. Do not drop or shock the valve seat cutter, or the dia-

mond particles may fall off.

3. Do not fail to apply engine oil to the valve seat cutter

before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.

NOTE

○

Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder in position, operate

the cutter in one hand. Do not apply too much force to
the diamond portion.

NOTE

○

Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking
to the cutter with washing oil.

5. After use, wash it with washing oil and apply thin layer

of engine oil before storing.

Marks Stamped on the Cutter

The marks stamped on the back of the cutter [A] represent

the following.
60° ........................... Cutter angle [B]
37.5

....................... Outer diameter of cutter [C]

Operating Procedures

•

Clean the seat area carefully.

•

Coat the seat with machinist’s dye.

•

Fit a 45° cutter into the holder and slide it into the valve
guide.

•

Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.

NOTICE

Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylin-
der head must be replaced.

ENGINE TOP END 5-31

Valves

•

Measure the outside diameter of the seating surface with
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind until the diameter is within the spec-
ified range.

Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 67.5° cutter
67.5° [F]

•

Measure the outside diameter of the seating surface with
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind [A] until the diameter is within the
specified range.

Original Seating Surface [B]

NOTE

○

Remove all pittings of flaws from 45° ground surface.

○

After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 67.5° grinding operation easier.

○

When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.

If the outside diameter [A] of the seating surface is too
large, make the 32° grind described below.
If the outside diameter of the seating surface is within the
specified range, measure the seat width as described be-
low.

•

Grind the seat at a 32° angle [B] until the seat outside
diameter is within the specified range.

○

To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.

○

Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.

NOTICE

The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.

○

After making the 32° grind, return to the seat outside di-
ameter measurement step above.

•

To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
outside diameter measurement step above.

5-32 ENGINE TOP END

Valves

If the seat width is too wide, make the 67.5° [A] grind
described below.
If the seat width is within the specified range, lap the valve
to the seat as described below.

•

Grind the seat at a 67.5° angle until the seat width is within
the specified range.

○

To make the 67.5° grind, fit 67.5° cutter into the holder,
and slide it into the valve guide.

○

Turn the holder, while pressing down lightly.

○

After making the 67.5° grind, return to the seat width mea-
surement step above.

Correct Width [B]

•

Lap the valve to the seat, once the seat width and outside
diameter are within the ranges specified above.

○

Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.

○

Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.

○

Repeat the process with a fine grinding compound.

Lapper [A]
Valve Seat [B]
Valve [C]

•

The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refaced too much; replace it.

•

Be sure to remove all grinding compound before assem-
bly.

•

When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Inspection in the Periodic
Maintenance chapter).

5-34 ENGINE TOP END

Cylinder, Pistons

Cylinder Removal

•

Remove:

Cylinder Head (see Cylinder Head Removal)
Bolt [A]
Water Hose Clamp Screw (Loosen) [B]
Water Pipe [C] and Hose
Cylinder [D]

Cylinder Installation

NOTE

○

If a new cylinder is used, use a new piston ring.

•

Replace the cylinder gasket [A] with a new one.

•

Install the dowel pins [B] and new cylinder gasket.

•

The piston ring openings must be positioned as shown.
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]
Upper Oil Ring Steel Rail [C]
Lower Oil Ring Steel Rail [D]
Oil Ring Expander [E]
Dent [F]
30

∼

40° [G]

•

Apply molybdenum disulfide oil solution to the cylinder
bore, piston rings and piston skirt.

•

Prepare two auxiliary head bolts [A] with their head cut.

○

Install the two bolts diagonally in the crankcase.

•

Position the crankshaft so that the piston heads are al-
most level.

•

Install the cylinder block [B].

○

Insert the piston rings with your thumbs.

•

Install the removed parts (see appropriate chapters).

Piston Removal

•

Remove the cylinder (see Cylinder Removal).

•

Place a clean cloth under the pistons and remove the pis-
ton pin snap ring [A] from the outside of each piston.

ENGINE TOP END 5-35

Cylinder, Pistons

•

Remove the piston pins.

Special Tool - Piston Pin Puller Assembly [A]: 57001-910

•

Remove the pistons.

•

Carefully spread the ring opening with your thumbs and
then push up on the opposite side of the ring [A] to remove
it.

•

Remove the 3-piece oil ring with your thumbs in the same
manner.

Piston Installation

•

Apply molybdenum disulfide oil solution to the oil ring ex-
pander, and install the oil ring expander [A] in the bottom
piston ring groove so the ends [B] not butt together.

•

Apply molybdenum disulfide oil solution to the oil ring steel
rails, and install the oil ring steel rails, one above the ex-
pander 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".

•

Do not mix up the top and second ring.

•

Install the top ring [A] so that the "1R" mark [B] faces up.

•

Install the second ring [C] so that the "RN" mark [D] faces
up.

○

Apply molybdenum disulfide oil solution to the piston
rings.

5-36 ENGINE TOP END

Cylinder, Pistons

NOTE

○

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

•

Install the piston with its dent mark facing forward.

•

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.

○

Apply molybdenum disulfide oil solution to the piston pins
and piston journals.

○

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.

•

Install the cylinder (see Cylinder Installation).

Cylinder Wear Inspection

•

Since there is a difference in cylinder wear in different di-
rections, take a side-to-side and a front-to-back measure-
ment at each of the two locations (total of four measure-
ments) shown.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, replace the cylinder.

10 mm (0.39 in.) [A]
60 mm (2.36 in.) [B]

Cylinder Inside Diameter

Standard:

61.994

∼

62.010 mm (2.4407

∼

2.4413 in.)

Service Limit: 62.09 mm (2.4445 in.)

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 pis-
ton.

Piston Diameter

Standard:

61.969

∼

61.984 mm (2.4397

∼

2.4403 in.)

Service Limit: 61.82 mm (2.4339 in.)

ENGINE TOP END 5-37

Cylinder, Pistons

Piston Ring, Piston Ring Groove Wear Inspection

•

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

•

With the piston rings in their grooves, make several mea-
surements with a thickness gauge [A] to determine piston
ring/groove clearance.

Piston Ring/Groove Clearance

Standard:

Top

0.03

∼

0.07 mm (0.0012

∼

0.0028 in.)

Second

0.02

∼

0.06 mm (0.0008

∼

0.0024 in.)

Service Limit:

Top

0.17 mm (0.0067 in.)

Second

0.16 mm (0.0063 in.)

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] 0.81

∼

0.83 mm (0.0319

∼

0.0327 in.)

Service Limit:

Top

0.92 mm (0.0362 in.)

Second

0.91 mm (0.0358 in.)

If the width of any of the two grooves is wider than the
service limit at any point, replace the piston.

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] 0.77

∼

0.79 mm (0.0303

∼

0.0311 in.)

Service Limit:

Top

0.70 mm (0.028 in.)

Second

0.70 mm (0.028 in.)

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 un-
even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.

5-38 ENGINE TOP END

Cylinder, Pistons

Piston Ring End Gap Inspection

•

Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Set it close to the
bottom of the cylinder, where cylinder wear is low.

•

Measure the gap [B] between the ends of the ring with a
thickness gauge.

Piston Ring End Gap

Standard:

Top

0.15

∼

0.30 mm (0.0059

∼

0.0118 in.)

Second

0.40

∼

0.55 mm (0.0157

∼

0.0217 in.)

Oil

0.20

∼

0.70 mm (0.0079

∼

0.0276 in.)

Service Limit:

Top

0.6 mm (0.024 in.)

Second

0.9 mm (0.035 in.)

Oil

1.1 mm (0.043 in.)

If the end gap of either ring is greater than the service
limit, replace all the rings.

5-40 ENGINE TOP END

Muffler

WARNING

The muffler can become extremely hot during nor-
mal operation and cause severe burns. Do not re-
move the muffler while it is hot.

Muffler Body Removal

•

Remove:

Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Muffler Cover Clamp Screw [A] (Loosen)
Muffler Cover Bolts [B]
Muffler Cover [C]

•

Remove:

Clamp Bolt [A] (Loosen)
Mounting Nut and Bolt [B]
Muffler Body [C]

Muffler Body Installation

•

Replace the muffler body gasket [A] with a new one.

•

Install the muffler body gasket so that its chamfer side [B]
faces front [C].

Rear [D]

•

Install the muffler body [A] and mounting bolt [B].

•

Fit the muffler body tooth and the muffler body clamp hole
[C].

•

Install the muffler body clamp bolt [D].

•

Tighten:

Torque - Muffler Body Mounting Bolt: 30 N·m (3.1 kgf·m, 22

ft·lb)

Muffler Body Clamp Bolt: 13 N·m (1.3 kgf·m, 115

in·lb)

ENGINE TOP END 5-41

Muffler

If the pad [A] was removed, attach the pad as follows:

•

Align the end of slit [B] on the pad with the bending point
[C] of the edge line on the muffler cover [D].

•

Align the center line [E] of the pad with the edge line [F]
on the muffler cover to attach the pad.

•

Insert the claw [A] into the cover clamp [B] and tighten the
clamp screw [C] as shown.

∼

55° [D]

Torque - Muffler Cover Clamp Screw: 6.9 N·m (0.70 kgf·m,

61 in·lb)

•

Insert the muffler cover [A] into the muffler body claw
(grommet) [B].

•

Install the muffler cover bolt [A] .

•

Tighten:

Torque - Muffler Cover Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Thoroughly warm up the engine, wait until the engine
cools down, retighten all the bolts and screw.

•

Install the removed parts (see appropriate chapters).

5-42 ENGINE TOP END

Muffler

Exhaust Pipe Removal

•

Remove:

Muffler Body (see Muffler Body Removal)
Oxygen Sensor (see Oxygen Sensor Removal in the
Electrical System chapter)
Mounting Bolt [A]

•

Remove:

Exhaust Pipe Holder Nuts [A]
Exhaust Pipe [B]

Exhaust Pipe Installation

•

Replace the exhaust pipe gaskets and muffler body gas-
ket with new ones.

•

Install the exhaust pipe.

•

Tighten:

Torque - Exhaust Pipe Holder Nuts: 12 N·m (1.2 kgf·m, 106

in·lb)

Exhaust Pipe Mounting Bolt: 20 N·m (2.0 kgf·m,

15 ft·lb)

•

Install the removed parts (see appropriate chapters).

CLUTCH 6-1

Clutch

Table of Contents

Exploded View........................................................................................................................

6-2

Specifications .........................................................................................................................

6-4

Special Tool and Sealant ........................................................................................................

6-5

Clutch Lever and Cable ..........................................................................................................

6-6

Clutch Lever Free Play Inspection ....................................................................................

6-6

Clutch Lever Free Play Adjustment ..................................................................................

6-6

Clutch Cable Removal ......................................................................................................

6-6

Clutch Cable Installation ...................................................................................................

6-6

Clutch Cable Lubrication...................................................................................................

6-6

Clutch Lever Installation....................................................................................................

6-6

Clutch Cover...........................................................................................................................

6-7

Clutch Cover Removal ......................................................................................................

6-7

Clutch Cover Installation ...................................................................................................

6-7

Release Shaft Removal ....................................................................................................

6-7

Release Shaft Installation .................................................................................................

6-8

Clutch Cover Disassembly................................................................................................

6-8

Clutch Cover Assembly.....................................................................................................

6-8

Clutch .....................................................................................................................................

6-9

Clutch Removal.................................................................................................................

6-9

Clutch Installation..............................................................................................................

6-9

Clutch Plate Wear and Damage Inspection ......................................................................

6-12

Clutch Plate Warp Inspection............................................................................................

6-12

Clutch Spring Free Length Inspection...............................................................................

6-12

Clutch Housing Finger Inspection .....................................................................................

6-12

Clutch Housing Spline Inspection .....................................................................................

6-13

Clutch Pressure Plate and Clutch Hub Inspection ............................................................

6-13

Kawasaki Ninja 300 / Ninja 300 ABS Motorcycle. Service Manual (2013) - page 8