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Table of Contents
•Apply clean engine oil to the piston rings
and
cylinder
walls.
•Compress
the piston rings
using
piston
ring
compressor
assemblies (special
tools).
A. Piston Ring Compressor Assembly (57001-921)
•Being careful not to break the piston
rings, push
the
cylinder block
down
carefully until
the
bottom of
each
cylinder clears the piston rings.
•Remove
the
special tools.
•Push the cylinder block down further
until
it bottoms.
•Make sure
that
the two knok pins are properly fitted
in the
cylinder
block.
•Put
on the new cylinder head gasket with the wider
bore grommets in
t
he
gasket
faci ng
up.
•Pu
t
on
the
O
rings (2). Replace the
O
rings with
new
ones
if
they are deteriorated or damaged.
A
.
Bore Grommet
C. 0 Rings
B.
Knock
Pins
Install
the cylinder
head
(Pg. 48)
.
Install
the camshaft (Pg.
47).
•AdjustJhe
camshaft
chai
n (Pg. 16),
and
install
th
e
cam·
shaft chain
tensioner
cap and
O
ring.
•Install
the cylinder
head
cover
(Pg.
44).
•Ad
just
the valve clearance (Pg. 16).
•Adjust the
ignitio
n
timing (Pg. 12).
•I nstall the carbu
retors
(Pg. 39).
•Install the mufflers (Pg. 44).
•Install the fuel tank
(Pg.
39)
.
DISASSEMBLY-ENGINE INSTALLED 53
PISTONS, PISTON RINGS
Removal:
•Remove the fu
el
tank
(Pg.
39).
•Remove the carburetors (Pg.
39).
Removal
of the
th rottle cables from the carbu retors is
not
necessary,
but pu
t
the
car
buretors
on
the
frame to avoid cable
stretch or carburetor
damage.
•Remove the muffl
ers
(Pg.
44)
.
•Remove the cylinder head
cover
(Pg.
44}.
•Remove
the
camshaft (Pg. 47).
•Remove the
cyli
nder
head (Pg.
48).
•Remove the
cylinder bloc
k (Pg.
52).
•Wrap
a clean
cloth
around
the
base of
each piston to
secure
it
in
position
for
removal
and
so
that
no parts
o
r dirt wil
l fal
l
into the
crankcase.
• Remove the
piston
pin
snap ring
from
the outside
of
each
piston.
A. Snap Ring
•Remove each piston
by
pushing its piston pin out the
side
that the
snap
ring
was
removed.
If necessary,
use
the piston pin
pu ller and
adapter "B"
(special
tools).
A.
Piston Pin Puller (57001-910)
B.
Adapter "B" (57001-913)
•Remove the pisto
n rings
with
the piston
ring
pliers
(special tool
).
To
remove a ring by
h,ind
,
sp read
the
ring open
with
both thumbs,
and
then
push up
on
the opposite
side.

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Table of Contents

   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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