Kawasaki Z1000SX - Service manual > Piston Installation

• Apply molybdenum disulfide oil solution to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together
• Apply molybdenum disulfide oil solution to the oil ring steel rails, and 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.

NOTE

• The oil ring rails have no "top" or "bottom".

 

• Do not mix up the top and second ring.
• Install the top ring [A] so that the "1T" mark [B] faces up.
• Install the second ring [C] so that the "2T" mark [D] faces up.
  • Apply molybdenum disulfide oil solution to the piston rings.

NOTE

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

 

• Install the piston with its dent mark facing forward.
• Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole.
  • Apply molybdenum disulfide oil solution to the piston pins and piston journals.
  • When installing the piston pin snap ring, compress it only enough to install it and no more.

NOTICE Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

• Install the cylinder (see Cylinder Installation).

Cylinder Wear Inspection

• Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) as shown in the figure.

  If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder.

  10 mm (0.39 in.) [A]
  60 mm (2.36 in.) [B]

Cylinder Inside Diameter
 Standard: 76.990 - 77.006 mm (3.0311 - 3.0317 in.)
 Service Limit: 77.09 mm (3.035 in.)

Piston Wear Inspection

• Measure the outside diameter [A] of each piston 11 mm (0.43 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin.

  If the measurement is under service limit, replace the piston.

Piston Diameter
 Standard: 76.974 - 76.984 mm (3.0305 - 3.0309 in.)  Service Limit: 76.82 mm (3.024 in.)

Piston Ring, Piston Ring Groove Wear Inspection

• Check for uneven groove wear by inspecting the ring seating.

  The rings should fit perfectly parallel to groove surfaces.

  If not, replace the piston and all the piston rings.

• With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance.

Piston Ring/Groove Clearance
 Standard:
  Top 0.03 - 0.07 mm (0.0012 - 0.0028 in.)
  Second 0.02 - 0.06 mm (0.0008 - 0.0024 in.)
 Service Limit:
  Top 0.17 mm (0.0067 in.)
  Second 0.16 mm (0.0063 in.)

Piston Ring Groove Width Inspection

• Measure the piston ring groove width.
  • Use a vernier caliper at several points around the piston.

Piston Ring Groove Width
 Standard:
  Top [A] 0.82 - 0.84 mm (0.0323 - 0.0331 in.)
  Second [B] 0.81 - 0.83 mm (0.0319 - 0.0327 in.)
 Service Limit:
  Top [A] 0.92 mm (0.0362 in.)
  Second [B] 0.91 mm (0.0358 in.)

If the width of any of the two grooves are wider than the service limit at any point, replace the piston.

Piston Ring Thickness Inspection

• Measure the piston ring thickness.
  • Use the micrometer to measure at several points around the ring.

Piston Ring Thickness
 Standard:
  Top [A] 0.77 - 0.79 mm (0.0303 - 0.0311 in.)
  Second [B] 0.77 - 0.79 mm (0.0303 - 0.0311 in.)
 Service Limit:
  Top [A] 0.70 mm (0.028 in.)
 Second [B] 0.70 mm (0.028 in.)

If any of the measurements is less than the service limit on either of the rings, replace all the rings.

NOTE

• When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston.

Piston Ring End Gap Inspection

• Place the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low.
• Measure the gap [B] between the ends of the ring with a thickness gauge.

Piston Ring End Gap
 Standard:
  Top 0.20 - 0.30 mm (0.0079 - 0.0118 in.)
  Second 0.38 - 0.48 mm (0.0150 - 0.0189 in.)
 Service Limit:
  Top 0.6 mm (0.024 in.)
  Second 0.8 mm (0.031 in.)

If the end gap of either ring is greater than the service limit, replace all the rings.

See also: