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Cylinder Removal; Cylinder Installation Notes; Piston Removal - Kawasaki KX125 1990 Service Manual

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4-12 ENGINE TOP END
...............................................................
Cylinder.
Piston
...............................................................
Cylinder Removal
-
Drain
the
coolant
'
Remove
the
following
parts:
Cylinder
Head
Clutch Cable lower
End
(KX125)
'
l
oosen
the
clamps,
and pull the ca
rburetor
out
of
the holder
and
the
air
cleaner
duct
(KX250).
-
Remove the
carburetor
holder mounting bolts, and
pull
the
hol
der out
1.0
the
rear (KX250).
-
Remove
the
right
cover
at
the
cylinder.
-
Remove the
shaft
lever
mounting bolt or
nut,
and
take
off
the
shaft
lever.
A.
Shaft l
eve
r
CAUTION
Exhaust valve operating shaft lever nut for the
KX125 has left·hand
threads.
'
Remove
the cylinder nuts
.
-
lift
off
the cyH
nder.
and
remove the cy linder
base
gasket.
If
necessary,
tap
lightly
around
the
base
of
the
cyli
nder
with
a plastic
ma
llet,
taking
ca re
not
to damage
the
cylinder.
A.
Plastic
Ma llet
-
Re move
the exhaust
va
lves
from
the
cylinder.
Cylinder Installation Notes
-I
nstallation
is
the
reverse of remova
l.
-
Scrape a ny
carbon
out of the ex
hau
st
port.
-
Check for a
crust
of minerals
and rust in the
cylinder
water
jacket. a
nd
remove
them
if
necessary.
-
Replace the cylinder
base
gasket with
a
new
one.
-
Apply engine
oil
to
the piston
surface,
piston
rings
and
cylinder
bore.
-Check to see
that the
pin in
each
piston ring groove
is between
the
ends of
the
piston
ring,
and
fit the
base
of the cylinder over
each
ring,
pressing
in
on
oPfX>Site
sides of
the
ring
as
necessary.
Be
certain
that
the rings
do
not slip out
of
position.
-
Tighten
the
cylinder
nuts to
the specified
torque.
T.ghtenlng
Torque
:
KX125
:
25 N·m 12.6
kg-m.
18 fHbl
KX250
:
34 N·m 13.5
kg·m.
25 fHbl
-
Tighten
the shaft lever nut
to
the specified
torque.
Tightening
Torque
KX126:
8 .3 N-m 10.85 kg-m
.
74
in-Ibl
KX260:
9 .8 N-m 11 .0
kg-m.
87 in-tb)
-
Refer
to
Carburetor
Insta llation
Notes
in
the Fuel
System chapter
for
carburetor
installation.
Piston
Removal
-
Remove
the
cylinder.
-
Stuff
a
clean
cloth into
the
cra nkcase
opening
around
the
connecting
rod
so
that
no
parts will
fall into the
crankcase.
-
Remove
one
o
f
the
piston pin snap
rings
with
needle
nose
pliers.
-
Remove
the
piston
by
pushing
the
piston
pin
out the
side
from which
the snap ring
was
removed.
Use a
piston pin
pu
ller
assembly
(special
toot),
if the
pin
is
tighl
A.
Piston
Pin Pu ller
Assembly:
57001-910

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