Need a diagram for an engine of a zxr9 kawasaki motorbike

You could purchase a service manual for the 250. Then you will need tools, some very special. You will need a place to work and probably a mechanic friend to look over your shoulder from time to time. You should speak with the parts guy or gal at the Kawasaki shop considering the parts you will need for this 25 year old motorcycle. I'm sorry, you can not get step by step instructions on how to reassemble an engine here

Since you are this far along, you may well want to consider the actual condition of the engine. Bore clean and smooth? Piston? Bearings, etc. You may also want to consider the general condition of the bike. Consider, when you are all done, you will have a very expensive 25 year old motorcycle. This is not impossible but it will be an involved expensive project.

Please take a second opinion to confirm . Now if the perrformance of the bike engine is poor, low fuel efficiency , poor torque and poor start specially when it is cold then you need to check the COMPRESSION of the cylinder and ONLY if this is low should you need to replace. Also if there is heavy smoking or use of engine oil then the oil rings can be faulty.

Yes, the problem is linked to compression getting past the rings. The pressure goes to the gearbox then some oil gets carried out of the box along with the compression. Too much oil in the gearbox makes the problem even worse. You shouldn't need pistons. Chances are the rings are just stuck in the piston ring grooves. Sometimes they can be freed up by the mechanic manipulating them. Often they break when manipulated. It all depends on how badly they are stuck. If a piston is badly scored it needs to be replaced. The scoring can stop the rings from sealing the cylinder. Do this; drain the oil then fill the box to the proper level. Wash the bike to rid it of previous oil spills. Now see if the problem returns after the washing. If the rings are stuck , the bike should be smoking as you start and ride it. Chances are that only the rings will need to be replaced. Any chance you can be there as the mechanic takes the cylinder off? A dishonest shop could bring you a badly scored piston and rings and say they came from your bike when in reality they came from another bike. They free up your rings and charge for new pistons and new rings as if they actually put them in.

No, their would be no reason to change the piston and rings first up, unless you know that they are worn from the previous owner, Get the bike up and running first and go from their, will be a good chance the piston and rings will be fine.

Change the oil first up as their is a good chance condensation has occurred and put water in to the oil. Drain the fuel from both the tank and carburettor, as this would have gone stale. Change battery or jump start if required.

suspect. With the spark plugs out, crank the engine over a few times. (ensure oil level correct) If it winds over all good, put a few drops off oil in the cylinders. This will help build compression. Re-fit spark plugs, Full choke and give it a shot. Away it should go! Aerostart or ether may come in handy.

Goodluck!

Here is the deal; Assuming the rings that were sent to you are the correct thickness for the piston ring grooves but were actually made for a 1st, 2nd or 3rd oversize piston, they may still be able to be used. Put a single ring into the cylinder. There should be an end gap of about .025 in the ring. If not, you can carefully grind the end of the ring by using a bench grinder or a rotary grinder. File off any rough edges. Re-fit in the cylinder and check the end gap. If you do not have a thickness guage, .025 is about the thickness of a paper matchstick. Once all rings have been fitted for cylinder size, mount them on the piston and put the bike back together. Please rate my answer. Thanks.

I think you have worn internal engine parts. To much oil is getting past the piston rings. Try installing new piston rings and honing the cylinder walls.

Is the bike locked up? Did the piston melt into the cylinder head?

If so you need to free up the piston to release the cylinder head.

You could try a little penetrating oil on the piston ring area and some heat. Then a wood stake and a mallet with a couple solid hits might unstick the rings.

Of course, after that...the head, rings and probably the piston are all gonna be scrap! Which they are anyway if the melted together right?

http://www.kawasaki.com/DefaultFrame.aspx?strContentURL=/Site/VIVehicleInformation/VIepc.asp?intCatalogID%3d2%26CatalogTypeID%3d4%26ProductTypeID%3d10%26ModelMarketingID%3d138%26ModelCode%3dKX500E15%26ModelYear%3d2003%26SHOWVEHTABS%3d1

This is a link to your bikes online parts list from Kawasaki. You can at least get part numbers for replacements if needed.

Good luck and be careful!

The shifting problem is a bent shift fork. It will only get worse and is expensive to fix. The smoke is probably getting past a exhaust pipe gasket. When you fix the shifting it would be a good time to rebuild the top end with new pistons and rings.

Your problem is quite simple as what you done is rebuilt it with new piston rings i expect ,,but what you dident know is how to go about it SO what you have done is to fit the rings upside down ,,or ,,you have broken the new one putting it in ,,or,, you have got the wrong ring for the job,,or you dident hone out the cylinder the correct way and you took the lip of the cylinder but to much ,,or ,,the piston groove was to big alowing the piston rings to flap as it goes up and down,,and if 2 or 3 ring piston the ring gaps have to be (being air cooled) reset at 4 thou(.0004")(per inch per bore) and all rings have to be staggered,, 4 ringed piston stag to N-S-E-WEST,3 Rings in a Triangle 2 rings Opersit each other and 1 ring any where if the piston isent pined.
So let me know how you get on and work by the above and you will have a good bike again. Ron
New gaskets and (no goo ) to fit them on with and away you go
Let me know how you get on Ron

possible bad rings allowing excessive oil seep up and wash spark out on next fire. do a compression check, ck for proper spark, and fuel....hope this helps