Kawasaki Brute Force 750 4x4i Offroad Vehicle User Manual


 
5-40 ENGINE TOP END
Cylinder and Piston
NOTE
The oil ring rails have no “top” or “bottom”.
Install the oil ring expander [A] in t he bottom piston ring
groove so the ends [B] butt together.
Install the oil ring steel rails, one above the expander and
one below it.
Spread the rail with y our thumbs, but only enough to fit
the rail over the piston.
Release the rail into the bottom piston ring groove.
Do not mix up the top ring and second ring.
Install the top ring [A] so that the R mark [B] faces up.
Install the second ring [C] so that the “ RN”mark[D]faces
up.
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° [F] of angle from the opening of the top
ring.
Top Ring [ A]
Second Ring [B]
Oil Ring Steel Rails [C]
Oil Ring Expander [D]
F mark [E] must be faced toward Front Side for front and
rear pistons
Opening Positions [G]
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 t he piston pin hole.
When installing the piston pin snap ring, compress it only
enough to install it and no more.
Apply engine oil to the cylinder bore and, piston skirt.
Install:
Dowel Pins [A]
New Cylinder Base Gasket [B]