Kawasaki WORKHORSE 250 (2003) [95/322] Engine top end 4 31
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Kawasaki WORKHORSE 250 (2003) [95/322] Engine top end 4 31

Kawasaki WORKHORSE 250 (2003) [95/322] Engine top end 4 31
ENGINE TOP END 4-31
Cylinder and Piston
Cylinder Removal
•
Remove:
Cylinder Head (see Cylinder Head Removal)
Front Chain Guide [A]
•
Lift off the cylinder [B], and remove the cylinder base gas-
ket. If necessary, tap lightly around the base of the cylin-
der with a plastic mallet, taking care not to damage the
cylinder.
○
Immediately stuff a clean cloth around the piston to pre-
vent parts or dirt from falling into the crankcase.
Cylinder Installation
NOTE
○
If a new cylinder is installed, be sure to check pis-
ton/cylinder clearance (see Piston/Cylinder Clearance).
•
Clean any remains of the old cylinder base gasket from
the bottom of the cylinder and the top of the crankcase.
•
Install:
Dowel Pins [A]
New Cylinder Base Gasket [B]
•
The arrow on the piston head must point toward the front
of the engine.
•
The piston ring openings must be positioned as shown.
The openings of the oil ring steel rails must be about 30°
∼ 150° of angle from the opening of the top ring.
TopRing[A]
Second Ring [B]
Oil Ring Expander [C]
Top Oil Ring Steel Rail [D]
Bottom Oil Ring Steel Rail [E]
Arrow Mark [F]
Front [G]
•
Apply molybdenum disulfide oil to the piston rings and
smear some oil inside the cylinder bore.
•
The rear camshaft c hain guide also fit inside the tunnel.
•
Fit the cylinder down over the piston and rings.
○
Hold the rings into their groove with your fingers so that
the cylinder does not catch on them.
•
Be sure the O-ring [A] is in place at the bottom of the
cylinder.
•
Push the cylinder down solidly against the crankcase.

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