Kawasaki J300 - Service manual > Cylinder Removal

• Remove the cylinder head (see Cylinder Head Removal).
• Loosen the water hose clamp screw and disconnect the water hose [A].

• Remove:
  Lower Camshaft Chain Guide [A]
  Cylinder Bolts [B]
  Cylinder [C] and Gasket

Cylinder Installation

NOTE

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

 

• Be sure that two dowel pins [A] are properly fitted in the crankcase.
• Replace the cylinder base gasket [B] with a new one.
• Install the new cylinder base gasket.

• Position the piston ring opening as follows.

  Top Ring [A]
  Second Ring [B]
  Upper Steel Rail [C]
  Expander [D]
  Lower Steel Rail [E]

• Apply molybdenum disulfide oil solution to the piston and cylinder bore.
• Apply molybdenum disulfide oil solution to the piston rings (see Piston Installation).
• Install the cylinder while compressing the piston rings with your fingers.
• Install the lower camshaft chain guide [A] securely.
  • Fit the projections [B] to the grooves [C].
• Tighten the cylinder bolts temporary.
• Install the removed parts (see appropriate chapters).

Piston Removal

• Remove the cylinder (see Cylinder Removal).
• Place a clean cloth under the piston.
• Remove the snap ring [A].

• Remove:
  Piston pin [A]
  Piston [B]

• Carefully spread the piston 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: