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Cylinder Removal; Cylinder Installation - Kawasaki KDX200 Service Manual

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Cylinder.
Piston
Cylinder Removal
.
Remove:
Expansion
Chamber
Carburetor
Cylinder Head
Cooling Hose
Remove the advancer shaft lever cover
[Al
on the
cylinder.
Remove
the
shaft lever nut
[Al
and take off the shah lever [8).
CAUTION
The shaft lever nul has left·hand threads. Turn the nul
clockwise
lor
loosening
.
Free the magneto leads from the clamp on the
cylinder.
Remove the cylinder nuts
.
lift
off the
cylinder
[Al,
and
remove the cylinder base gasket.
If
necessary,
tap lightly around the base of the cylinder wi th a plastic
mallet [8], taking care not to damage the
cy
linder.
Cylinder Installation
Scrape any carbon out of the exhaust ports .
Check lor a crust of minerals and rust in the cylinder water
jacket,
and
remove them as needed.
Replace the
cylinder
base gasket with a new one.
*11
a new piston and or new cylinder are instaned. apply a thin
coat
of
molybdenum disulfide grease on the new piston and
cylinder
bore
.
Apply 2-stroke engine oil to the piston
surface,
piston rings and
cylinder
bore.
Check to see
that
the pin in each piston ring g roove is between the
ends of the piston ring. and fit the base of the cylinder over each ring,
pressing in on opposite sides of the ring as
necessary.
Be certain that
the rings do
not
slip
out
of position
.
Torque the cylinder nuts
in
a
criss-cross panern.
Torque
-
Cylinder
Nuts:
25 N-m (2.5
kg-m,
18 fl-Ib)
ENGINE TOP END 4-7

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This manual is also suitable for:

Kdx220 1995-2006

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