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

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Not For Resale www.SmallEngineDiscount.com 5-30 ENGINE TOP END Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001–910 [A] • Remove the pistons. • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it. • Remove the 3-piece oil ring with your thumbs in the same manner. Piston Installation • Apply molybdenum disulfide oil solution to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. • Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the expander and one below it. ○Spread the rail with your thumbs, but only enough to fit the rail over the piston. ○Release the rail into the bottom piston ring groove. NOTE ○The oil ring rails have no “top” or “bottom”. Do not mix up the top and second ring. • Install the top ring [A] so that the "R" mark [B] faces up. ○Install the second ring [C] so that the "RN" mark [D] faces up. ○Apply molybdenum disulfide oil solution to the piston rings.
Cylinder, Pistons ENGINE TOP END 5-31 NOTE ○If a new piston is used, use new piston ring. Install the piston with its hollow facing forward. • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole. ○Apply molybdenum disulfide oil solution to the piston pins and piston journals. ○When installing the piston pin snap ring, compress it only enough to install it and no more. CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. • Install the cylinder (see Cylinder Installation). Cylinder Wear • Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) shown in the figure. If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder. [A] 10 mm (0.39 in.) [B] 60 mm (2.36 in.) Cylinder Inside Diameter Standard: 77.194 ∼ 77.206 mm (3.0391 ∼ 3.0396 in.) Service Limit: 77.30 mm (3.0433 in.) Piston Wear • Measure the outside diameter [A] of each piston 5 mm (0.20 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the piston. Piston Diameter Standard: Service Limit: 77.174 ∼ 77.184 mm (3.0383 ∼ 3.0389 in.) 77.02 mm (3.0323 in.) PistonRing,PistonRingGrooveWear • Check for uneven groove wear by inspecting the ring seating. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance. Piston Ring/Groove Clearance Standard Service Limit Top 0.04 ∼ 0.08 mm 0.18 mm (0.0016 ∼ 0.0031 in.) (0.0071 in.) Second 0.03 ∼ 0.07 mm 0.17 mm (0.0012 ∼ 0.0028 in.) (0.0067 in.) Not For Resale www.SmallEngineDiscount.com
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© 2002 Kawasaki Heavy Industries,
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General Specifications GENERAL INFO
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Torque and Locking Agent PERIODIC M
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Torque and Locking Agent PERIODIC M
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Periodic Maintenance Procedures •
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Periodic Maintenance Procedures PER
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FUEL SYSTEM (DFI) 3-1 Fuel System (
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FUEL SYSTEM (DFI) 3-21 Troubleshoot
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DFI System Troubleshooting Guide FU
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Inlet Air Pressure Sensor (Service
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Subthrottle Valve Actuator (Service
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Fuel Line • Open the fuel tank ca
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Crankcase Splitting • Apply liqui
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Crankshaft and Connecting Rods •
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Crankshaft and Connecting Rods CRAN
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Transmission CRANKSHAFT/TRANSMISSIO
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ELECTRICAL SYSTEM 16-1 Electrical S
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Ignition System ELECTRICAL SYSTEM 1
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Meter, Gauge, Indicator Unit ELECTR
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MODEL APPLICATION Year Model Beginn
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