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Cylinder, Piston; Cylinder Removal; Cylinder Installation; Piston Removal - Kawasaki KLX110 Service Manual

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Cylinder, Piston

Cylinder Removal

Removed the cylinder head.
Take out the cylinder block with lower camshaft chain guide, and
remove the gasket. There are knock pins on the cylinder base.
Wrap a clean cloth [A] around the base of the piston so that no parts
or dirt will fall into the crankcase.

Cylinder Installation

If the cylinder block is replaced with a new one, piston to cylinder
clearance must be checked against the specified value.
Install a new cylinder base gasket [A] and be sure that two knock pins
[B] are properly fitted in the crankcase.
Pull the camshaft chain taut top avoid kicking it and use a wrench on
the crankshaft to set the piston at BDC.
Position the piston ring opening as follows.
Top Ring – Front [A]
Second Ring – Rear [B]
Upper Steel Rail – About 30
Expander – Rear [D]
Lower Steel Rail – About 30
Piston [E]
Apply engine oil to the piston rings and the cylinder inside surface.
Pull the camshaft chain up through the cylinder and insert a screw-
driver to keep the chain from falling back into the engine.
Place the upper camshaft chain guide inside the cylinder blocks.
Fit the bottom of the cylinder over the piston rings, pressing in on
opposite sides of the rings as necessary. Take care that the rings do
not slip out of their proper positions.
Insert the lower camshaft chain guide [A] all the way down.
Install the cylinder head.

Piston Removal

Remove the cylinder.
Pliers [A]
Snap Ring [B]

of angle to the right [C]

of angle to the left [C]


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