Kawasaki STX-15F service manual With the Hand, With the Special Tools

ENGINE TOP END 6-33

Cylinder, Pistons

•The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 ∼ 40° of angle from the opening of the top ring. [A] Top Ring

[B] Second Ring

[C] Oil Ring Steel Rails

[D] Oil Ring Expander [E] Hollow (Exhaust Side)

•Replace the cylinder gasket with a new one, and install the pins [A] and new cylinder gasket.

Exhaust Side [B]

•Apply molybdenum disulfide oil solution to the cylinder bore, external of pistons and piston rings.

•Insert the piston in the cylinder by two methods.

With the Hand

•Position the crankshaft at #2, #3 piston TDC.

•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 crank- shaft at 90° angle.

○Insert the piston rings with your thumbs or the thin (–) screw driver.

With the Special Tools

•Install the two cylinder head bolts [A] diagonally in the crankcase.

•Slip the piston bases [B] under the pistons to hold them level.

•Compress the piston rings using the piston ring compres- sor grips [C] and piston ring compressor belts [D] with chamfered side upward.

Special Tools - Piston Base, 8: 57001-1604

Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 80 ∼ 91:

57001-1320

•Push down vigorously the cylinder aligning the cylinder bores with all the piston heads.

•Install the cylinder so that its angle aligns the piston angle after removing the piston ring compressor belts.

•Install the removed parts.