Kawasaki S2 (1972-1973) [23/129] Piston piston pin
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Kawasaki S2 (1972-1973) [23/129] Piston piston pin

Kawasaki KH400 (1974-1976) [23/129] Piston piston pin

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the piston and cylinder are made with a certain amount of clearance between them Piston seizure slap lubrication oil consumption com pression etc arc all closely related to this clearance When the cylinder is honed or if the cylinder is replaced the piston clearance must be measured and the standard value maintained Measure the cylinder inside diameter and the piston diameter at the points indicated in Fig 57 the difference between these two measurements is the piston cylinder clearance Compare the measured clearance with standard values in Table 5 Piston Clearance times with the throttle full open and read com pression If there is more that 14 Ibs sq in 1 kg cm2 difference between any two cylinder or if compression is less titan 70 of the specifie value piston piston rings or cylinder is worn Table 6 Compression Model S1 KH250 S2 S3 KH400 Standard 170 psi 12 0 kg crn2 700 r p m 156 psi 11 0 kg cm2 155 psi 10 9 kg cm2 640 r p m f Boring Honing If the cylinder gets out of tolerance due wear or to damage from piston seizure it can b restored to a usable condition by boring an honing When honing all cylinder diamet measurements must be within 0004 inch 0 0 mm of each other Oversize pistons are availab in two sizes 0 5 and 1 0 mm 0197 and 0394 i oversize CAUTION When the cylinder is bored or whe a new cylinder and piston are installed the engin must be properly broken in in the same mann as for a new vehicle 4 Assembly This is the reverse of disassembly NOTE 1 When inserting the piston into the cylinde align the ring opening with the knock pin in th ring groove and hold the ring down in the groo to prevent its hanging up on the edge of d cylinder 2 Spark plug installation torque is 18 0 22 ft lbs 2 5 3 0 kg M Table 5 Piston Clearance Model____ SI Eng No 0 04593 SI KH250 S2 S3 KH400 Standard Clearance_______________ 0 00083 0 00114 in 0 02 0 029 mm 0 00047 0 00079 in 0 012 0 020 mm 0 0OI 06 0 00138 in 0 027 0 035 mm 0 00307 0 00339 in 0 078 0 086 mm e Compression Confirm that the head is tightened down with 14 5 17 5 ft lbs 2 0 2 4 kg M torque and that there is no compression leakage at the head gasket Then thoroughly warm up the engine to bring piston clearance to normal and to be sure of sufficient lubrication oil between the piston and cylinder Next remove all spark plugs and insert a compression gauge firmly into one spark plug opening at a time allowing no compression 3 PISTON PISTON PIN While the engine is running constantly subjected to the high the burning gasoline and being a cool becomes extremely hot Due the piston temperature difficult part to differenc

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