Kawasaki KLE500 (2004) [144/401] 32 engine top end
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Kawasaki KLE500 (2004) [144/401] 32 engine top end

Kawasaki KLE500 (2004) [144/401] 32 engine top end
5-32 ENGINE TOP END
Cylinder, Piston
Cylinder Removal
•
Remove the cylinder head (see Cylinder Head Removal).
•
Remove the main oil pipe mounting bolt.
•
Remove the bolts [A] and pull out the water pipe with wa-
ter pump cover [B] (see water pump removal in the Cool-
ing System chapter).
•
Take out the cylinder block so as not to damage the main
oil pipe.
Cylinder Installation
•
Install:
Dowel Pins [A]
New Cylinder Base Gasket [B]
○
Install the cylinder base gasket so that the swallen groove
come to upper side.
•
Apply molybdenum disulfide oil to the cylinder bore.
•
Position the crankshaft so that all the piston heads are
almost level.
•
Install the cylinder block [A].
Special Tool - Piston Ring Compressor Grip: 5700-1095
[B]
Piston Ring Compress o r Belt,
67 ∼ 79:
5700-1097 [C]
Piston Base,
2.3: 5700-1336 [D]
○
Insert the piston rings with your thumbs, if the special tools
are not available.
Piston Removal
•
Remove the cylinder (see Cylinder Removal).
•
Wrap a clean cloth [A] around the base of each piston to
secure it in position for removal and so that no parts and
dirt will fall into the crankcase.
•
Remove the piston pin snap rings [B] from the outside of
each piston.
•
Remove the piston by pushing its piston pin puller out the
side from which the snap ring was removed. Use a piston
pin puller, if the pin is tight.
Special Tool - Piston Pin Puller Assembly: 57001-910 [A]

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