Kawasaki WORKHORSE 250 (2003) [96/322] 32 engine top end
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Kawasaki WORKHORSE 250 (2003) [96/322] 32 engine top end

Kawasaki WORKHORSE 250 (2003) [96/322] 32 engine top end
4-32 ENGINE TOP END
Cylinder and Piston
Piston Removal
•
Remove the cylinder (see Cylinder Removal).
•
Place a clean cloth under the piston, remove the one of
the piston pin snap rings.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
•
Push out the piston pin, and remove the piston.
○
If necessary, use the piston pin puller assembly [A].
Special Tool - Piston Pin Puller Assembly: 57001-910
•
Remove the top and second piston rings [A].
○
Spread the ring open with your thumbs.
○
Push up on the opposite side with your fingers.
○
If necessary, use the piston ring pliers.
Special Tool - Piston Ring Pliers: 57001-115
•
Remove the oil ring upper and lower steel rails.
•
Spread the rail open with your thumbs.
○
Push up on the opposite side with your fingers.
•
Remove the oil ring expander.
Piston Installation
NOTE
○
If a new piston is used, check piston to cylinder clear-
ance (see Piston/Cylinder Clearance), and use new pis-
ton rings.
○
The oil ring rails have no “top” or “bottom”.
•
Install the oil ring expander [A] in the bottom piston ring
groove so the ends [B] butt together.
•
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.

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