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Cylinder, Piston; Cylinder Removal; Cylinder Installation - Kawasaki KLX110 Service Manual

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Cylinder, Piston

Cylinder Removal

Remove:
Cylinder Head (see Cylinder Head Removal)
Lower Camshaft Chain Guide [A]
Tap the cylinder [B] lightly with a plastic mallet to separate
from the crankcase.
Remove the cylinder base gasket.

Cylinder Installation

If the cylinder block is replaced with a new one, piston to
cylinder clearance must be checked against the speci-
fied value.
Install a new cylinder base gasket [A] and be sure that
two dowel pins [B] are properly fitted in the crankcase.
Pull the camshaft chain taut top avoid kinking it and use
a wrench on the crankshaft to set the piston at BDC.
Position the piston ring opening as follows.
Top Ring [A]
Second Ring [B]
Upper Oil Ring Steel Rail [C]
Oil Ring Expander [D]
Lower Oil Ring Steel Rail [E]
30 ∼ 90° [F]
Apply engine oil to the piston rings and the cylinder inside
surface.
Pull the camshaft chain up through the cylinder and insert
a screwdriver to keep the chain from falling back into the
engine.
Place the upper camshaft chain guide inside the cylinder
blocks.
Fit the bottom of the cylinder over the piston rings, press-
ing in on opposite sides of the rings as necessary. Take
care that the rings do not slip out of their proper positions.
Insert the lower camshaft chain guide [A] all the way
down.
Install the cylinder head (see Cylinder Head Installation).
NOTE
ENGINE TOP END 4-33

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   Also See for Kawasaki KLX110

This manual is also suitable for:

Klx110l

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