Kawasaki Z1000SX - Service manual > Cylinder Removal

• Remove:
  Lower Radiator Bolt [A]
  Radiator Bracket Bolt [B]
  Radiator Bracket [C]
  Cylinder Head (see Cylinder Head Removal)
  Engine Bracket (see Engine Removal in the Engine Removal/ Installation chapter)

• Remove:
  Water Hose Clamp Screw (Loosen) [A]
  Water Hose [B]

• Remove:
  Upper Engine Mounting Bolts (Both Sides) [A]
• Loosen:
  Upper Adjusting Collar Locknut [B]
  Special Tool - Engine Mount Nut Wrench [C]: 57001-1450
• Loosen:
  Upper Adjusting Collar [D]

• Remove:
  Cylinder [A]

NOTE

• If it is hard to remove it, tap lightly using a plastic-faced mallet [B].

Cylinder Installation

NOTE

• If a new cylinder is used, use new piston ring.

 

• Replace the cylinder gasket [A] with a new one.
• Install the dowel pins [B] and new cylinder gasket.
• Apply molybdenum disulfide oil solution to the cylinder bore.

• The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 - 40º of angle from the opening of the top ring.

  Top Ring [A]
  Second Ring [B]
  Upper Oil Ring Steel Rail [C]
  Oil Ring Expander [D]
  Lower Oil Ring Steel Rail [E]
  Dent [F]
  30 - 40º [G]

• Position the crankshaft at #2, 3 piston TDC.
• Prepare two auxiliary head bolts with their head cut.
  • Install the two cylinder head bolts [A] diagonally in the crankcase.
• Install the cylinder block [B].

  Pistons [C]

  • First insert the #2, 3 pistons, and then rotate the crankshaft at 90º angle.
• Tighten the upper engine mounting bolts and engine bracket bolts after cylinder head bolts tightend.

Piston Removal

• Remove the cylinder (see Cylinder Removal).
• Place a clean cloth under the pistons and remove the piston pin snap ring [A] from the outside of each piston.

• Remove the piston pins.

  Special Tool - Piston Pin Puller Assembly [A]: 57001-910

• 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.

See also: