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Piston Removal; Piston Installation - Kawasaki KX85 Service Manual

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Also See for KX85
Brochure - 13 pages
Service manual - 332 pages
Owner's manual - 172 pages

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Cylinder

Piston Removal

Remove the cylinder (see Cylinder Removal).
Stuff a clean cloth into the crankcase opening around the
connecting rod so that no parts will fall into the crankcase.
Remove one of 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
puller assembly [A], if the pin is tight.
Special Tools - Piston Pin Puller Assembly: 57001-910
Carefully spread the ring [A] opening with your thumbs
and then push up on the opposite side of the ring to re-
move it.

Piston Installation

Stuff a clean cloth into the crankcase opening around the
connecting rod so that no parts will fall into the crankcase.
Scrape off any carbon of the piston, then lightly polish the
piston with fine emery cloth.
Clean carbon and dirt out of the piston ring groove using
a suitable tool.
Carbon particles can be very abrasive to piston
ring. Don't allow such particles to fall onto the
cylinder walls.
The top [A] and second [B] rings are identical in KX100
model, But they are different in KX85 model.
The mark on the ring are as follows;
KX85A/B-
Top: 1N
Second: 2N
KX100D-
Top and Second: N
First fit one end of the piston ring against the pin in the
ring groove, spread the ring opening with the other hand
and then slip the ring into the groove.
Install each ring so that the marked [C] side faces upward.
NOTICE
ENGINE TOP END 4-7

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   Also See for Kawasaki KX85

This manual is also suitable for:

Kx85-iiKx100

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  • Julie Williams Jul 17, 2019 11:44:
    Can you please help me identify two engine years by the engine number and not the vin?

    1. KX085AE037​876

    2. KX085AE015​215

    Any help would be greatly appreciate​d.

    Thank you. Julie.
  • jeesus Jun 10, 2015 09:46:
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