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Kawasaki Z250 1981 Service Manual Page 86

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80 DISASSEMBLY-ENGINE REMOVED
•Fit the
engine sprocket and spl
ined washer
on the
output shaft, and
screw
on
the engine
sprocket
nut.
•Tighten the
nut to
7.0 kg-m (51
f
t-l
bs) of torq
ue,
using
the engine sprocket holder (special
tool)
to hold
t
he
engine sprocket steady.
•Bend part of splined
washer
over
the side of
the nut.
•Install t
he
drive chain guard and its screws
(3).
A. Drive Chain Guard
•Make sure
that the
two
knock
pins arc in
place,
and
fit
a
new
left engine
cover
gasket.
•Instal
l
the
left
engine cover and its screws
(9).
•Apply
~ngine
oil to the piston pins, and install the
piston
and piston
pins.
The arrow on
the top
of
each
piston must
point toward
the
front of
the
engine.
A.
Arrow
B. Front
•Fit a
new
piston
pin
snap
ring
into
the side of
each
piston, taking
care
not
to compress
it too
much. Check
that the other snap rings are
in
place.
{I~~1Efil
~~g
n~t
:::~e~:~
o~~~n::f~~!:d
~:n;:
moval, and it may slip out and score the cylinder wall.
•Make
sure that the two
knock pins are properly in
place, and fit a new
cylinder
base gasket.
•Turn the
crankshaft
until the
height
of both
pistons
is
the
same,
while
pu
lling the camshaft
chain taut to
prevent the chain
from
snagging.
•To
position the pistons during
cylinder block installa-
tion,
use
the
piston holders
(special tools) in the front
and
rear of
the
pistons.
A. Piston Holders (57001-1023)
·•Position each
piston
ring
so
that
the
opening
in
the
top
and
oil
ring
of
each piston
is facing forwards, and the
second ring opening faces the rear. The
openings
of
the
oil
ring steel
rails
mu
st
be
slipped to both d
irections
about 30° from the
opening
of
the expander.
Piston Rings
A.
Openings
•Apply
a clean engine oil
to
the
piston
rings and
cyl-
inder
walls.
•Compress
the piston
rings
using
piston
ring
compressor
assemblies (special tool).
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
until
it bottoms.
•Using
ccmpressed
air,
blow out any particles
which
may
obstruct the
oil passages
in
the cylinder
head.

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Kz350 1981

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