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Kawasaki KZ1300-A1 Quick Reference Manual Page 182

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MAINTENANCE--ENGINE
CYLINDER BLOCK, PISTONS
The inspection and maintenance of cylinder block
and the pistons include the following items.
OCompression measurement
OCylinder, piston wear
oPiston/cylinder clearance
OBoring, honing
oPiston/cyl inder seizure
oPiston cleaning
oPiston ring, piston ring groove wear
oPiston ring end gap
OPiston, piston pin, connecting rod wear
oWater pump shaft journal wear
oWater pump drive bevel gear inspection, and journal
wear
oWater pump bevel gear inspection, water pump shaft
journal wear
O
Timing advancer drive gear inspection
OCylinder bearing wear
Compression measurement
Before measuring compression, check that the battery
is fully charged (Pg. 230). Thoroughly warm up the
engine so that engine oil between the pistons and cylin-
der walls will help seal compression as it does during
normal
running.
While the engine is running, check that
there is no gas leakage from around the cylinder head
gasket and from the spark plugs.
Stop the engine, remove the spark
plugs,
and attach
the compression gauge (special tool) firmly into one
spark plug hole. Using the starter motor, turn the engine
over with the throttle fully open until the compression
gauge stops rising; the compression is the highest reading
obtainable. Repeat the measurement for the other cyl-
inder.
A.
Compression Gauge (67001-123)
Table H27
Cylinder
Compressiont
Usable
Range
8.4
-
12.0 kg/cm
2
(119-171 psi), or
less than 1 kg/cm
2
(14 psi)
difference
between any two
cylinders
t
Engine hot, spark plugs removed, throttle fully open-
ed, cranking the engine with the starter motor.
If cylinder compression
is
higher than the usable
range,
check the following
:
1. Carbon build-up on the piston head and cylinder
head -
c~an
off any carbon on the piston head and
cylinder head.
2. Cylinder head gasket, cylinder base gasket - use only
the proper gasket for the cylinder head. The use of
a gasket of incorrect thickness will change the com-
pression.
3. Valve stem oil seals and piston rings - rapid carbon
accumulation in the combustion chambers may be
caused by damaged valve stem oil seals and/or
dam-.
aged piston oil rings. This may be indicated by white
exhaust smoke.
4. Cylinder head volume (Pg. 174).
If cylinder compression
is
lower than the usable
range
,
check th
e
following:
1. Gas leakage around the cylinder head - replace the
damaged gasket and check the cylinder head warp
(Pg.174).
2. Condition of the valve seating (Pg. 177).
3. Valve clearance
(Pg.
12).
4. Piston/cylinder clearance, piston seizure
5. Piston ring, piston ring groove
Cylinder, piston wear
Since there is a difference in cylinder wear in differ-
ent directions, take a side-ta-side and a front-to-back
measurement at each of the 3 locations (total of 6
measurements) shown in Fig.
H52.
If any of the cylin-
der inside diameter measurements exceeds the service
limit,
the cylinder will have to be bored to oversize and
then
honed.
However, if the amount of boring necessary
would make the inside diameter greater than 62.5 mm,
the cylinder block must be replaced.
Cylinder Inside
Diameter
Table
H28
Service
Limit
60 mm
Rings
Cylinder
Inside
Diameter
62.10
mm,
or more than 0.05 mm
difference between any two
measure-
ments
182

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