Kawasaki Ninja 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
• Applymolybdenum 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”.

• Apply molybdenum disulfide oil solution to the piston rings.

NOTE

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 “T2” mark [D] faces up.

• Apply molybdenum disulfide oil solution to the piston pin and piston journal.

NOTE

If a new piston is used, use new piston rings.

• 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.

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.

• 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.

  Top Ring [A] Second Ring [B] Oil Ring Steel Rails [C] Oil Ring Expander [D] Hollow [E] 30 40° [F]

• Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt.
• Install the piston with itsmarking hollow [A] facing exhaust side.
• Using the piston ring compressor assembly [B] to install the piston from the cylinder head side.

Special Tools - Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67

79:
57001-1097

• Install: Crankshaft (see Crankshaft Installation) Connecting Rod Big End Caps (see Connecting Rod Installation)