Kawasaki Z1000 Motorcycle User Manual


 
ENGINE TOP END 5-31
Cylinder, Pistons
NOTE
If a new piston is used, use new piston ring.
Install the piston with its hollow facing forward.
Fit a n
ew piston pin snap ring into the side of the piston
so that the ring opening [A] does not coincide with t he 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
enou
gh to install it and no more.
CAUTION
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
Since there is a difference in cylinder wear in different di-
rections, take a side-to-side and a front-to-back measure-
ment at each of the two locations (total of four measure-
ments) shown in the figure.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, replace t he cylinder.
[A] 1 0 mm (0.39 in.)
[B] 6 0 mm (2.36 in.)
Cylinder Inside Diameter
Standard: 77.194 77.206 mm (3.0391 3.0396 in.)
S
ervice Limit:
7
7.30 mm (3.0433 in.)
Piston Wear
Measure the outside diameter [A] of each piston 5 m m
(0.20 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 pis-
ton.
Piston Diameter
Standard: 77.174 77.184 mm (3.0383 3.0389 in.)
Service Limit: 77.02 mm (3.0323 in.)
PistonRing,PistonRingGrooveWear
Check for uneven groove wear by inspecting the ring seat-
ing.
The rings should fit perfectly parallel t o groove surfaces.
If not, replace the piston and all the piston rings.
With the piston r ings in their grooves, make several m ea-
surements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groov e Clearance
Standard Service Limit
Top 0.04 0.08 mm 0.18 mm
(0.0016 0.0031 in.) (0.0071 in.)
Second 0.03 0.07 mm 0.17 mm
(0.0012 0.0028 in.) (0.0067 in.)