Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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Cylinder, Pistons
ENGINE TOP END 5-29
Cylinder Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Water Hose [A]
• Remove the cylinder [B].
Cylinder Installation
NOTE
○If a new cylinder is used, use new piston ring.
Install the pins [A] and new cylinder gasket [B].
• Apply engine oil to the cylinder bore.
• The piston ring openings must be positioned as shown in
the figure. The openings of the oil ring steel rails must be
about 30 – 40° of angle from the opening of the top ring.
[A] Top Ring
[B] Second Ring
[C] Oil Ring Steel Rails
[D] Oil Ring Expander
[E] Hollow
Position the crankshaft at #2, #3 piston TDC.
• Prepare two auxiliary head bolts with their head cut.
○Install the two cylinder head bolts [A] diagonally in the
crankcase.
•
Install the cylinder block [B].
Pistons [C]
○First insert the #2, #3 pistons, and then rotate the crankshaft
at 90° angle.
○Insert the piston rings with your thumbs or the thin (–)
screwdriver.
Piston Removal
Remove the cylinder (see Cylinder Removal).
• Place a clean cloth under the pistons and remove the piston
pin snap ring [A] from the outside of each piston.