How to..

geerbangr wrote: So what's the deal with the real McCoy as Patton showed a pic of ??

timebomb33 wrote: the reason i like to use chop sticks is they are longer and its easier to get in around the cylinder stud with them also they don't come apart like popsicle sticks sometimes do.

Patton wrote: Some folks use thin metal strips under the zip tie, whereby both slide down as the rings enter the bore. The strips may be cut from an aluminum can.)

OnkelB wrote: Assuming we're talking about a 4-cylinder engine (?) it's easier to install the two inside pistons first.

Install the base gasket and whatever o-rings, cam chain guides etc. you have there.

Rotate the crank until pistons 1 and 4 are all the way down and 2 and 3 are all the way up.

Insert wooden supports between the base gasket and pistons 2 and 3 (I made the supports pictured below in like 5 minutes) and rotate the crank until pistons 2 and 3 are resting against the supports and are as centered as possible.

Apply a thin coat of assembly lube or engine oil to the cylinder bores, slide the cylinder block onto the studs and insert the top of pistons 2 and 3 into their bores.

Compressing the rings with whatever you need (I've never used anything but my hands) gently slide/wiggle the block down over the rings - remember to space the ring gaps 120 degrees apart.

Once you have pistons 2 and 3 installed lift them off the supports by rotating the crank and remove the supports.

Rotate the crank so that 2 and 3 comes down and 1 and 4 comes up and repeat the above for pistons 1 and 4, there you go.

Edit: Btw, when installing the piston pin clips, DO NOT forget to stuff rags or whatever in the case holes around the rods, clips down the crank case is not a good thing. :whistle: :pinch:

racer54 wrote: Sounds like a lot of backyard shadetree mechanics around these here parts! Chop sticks, pop-sickle sticks, 2x4's, tin cans, plastic tie wraps, etc. etc. etc.....Kawasaki makes all these tools especially for helping and you use peices of wood laying around instead? Wow! I feel right at home...I use sticks and 2x4's myself... :whistle: Get the pistons started in bores and then using sticks start working rings up into the cylinder on both pistons, working back and forth til the cylinder drops down onto piston and then work on 1 and 4 and repeat. We don't need no stinking tools!