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  1. #1

    2000 kawi zxi 1100

    Hey guys new here.

    I just bought not long ago 1100 zxi and i m having 50 psi compression on one cylinder so i took head off and one piston is damage and cylinder has scratch on it.
    After some reading and using manual i pulled engine out today.
    I will bore all 3 cylinders and get new pistons.

    I we never done this before but i can use wrench pretty good.

    Can you guys please help me fix this right way and do all checks while its a part.
    What silicon lock tit grease to use to get job done right and please tell me if what ever s on your mind trick and tips.
    Any cheap mods to do while engine is out.

    Thanks for your time and your help.
    I


  2. #2
    steve45's Avatar
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    Use Kawasaki parts. At the very least do NOT use cheapo SBT parts.

    Make sure you check the piston ring end gaps. Torque head and cylinder base nuts in steps and use a torque wrench.

  3. #3
    Thanks for replay bro. I pulled cylinder off and there is a crack in cylinder so i m looking to bay new one from ebay. However i m getting new set pistons and rings and at least honing new cylinders, i do have torque wrench, and know how to use it, i will tighten them by manual specs and in the order.

    Should i polish manifold while its a part?
    How much does it help?

    Thanks again.

  4. #4
    steve45's Avatar
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    Won't hurt, but it probably won't help, either.

    Make sure to use Kawi gaskets on the intake side. My STX developed a leak today and I'm pretty sure it has aftermarket gaskets in it. I bought it used and had to put an engine in it with what I had on hand.

  5. #5
    What makes you think it wont help? What about water box mod?

  6. #6
    steve45's Avatar
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    What do you mean by polishing the manifold? Which manifold? Are you talking about Extrude Honing it?

    If you want better performance, start with a different impeller. Don't know much about a waterbox mod for the ZXi, waste of time and money on the Ultra 150--and people end up taking them off because of the noise.

  7. #7
    Do i have to bore this cylinders? 79.55 79.95. 80.03? Is it okay for 80mm standard pistons?

  8. #8
    steve45's Avatar
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    Check the clearance with a feeler gauge. I don't know the spec offhand.

  9. #9

    spec

    Quote Originally Posted by nismax View Post
    Do i have to bore this cylinders? 79.55 79.95. 80.03? Is it okay for 80mm standard pistons?
    yes bore them..your 79.55 is too small id should be 80.000-80.015 sl=80.10.
    piston [email protected] upskirt=79.865-79.880 sl=79.72
    p2c clear=0.13-0.14
    reg=.25-.40

    Remember the bore is three dimensional and does not wear equally. it is most likely out of round.

    As you can see the stock piston diameter already exceeds the size of the bore which is most likely do to an error in your measurements.

    Based on your numbers of 80.03 as the largest diameter I would not purchase the .25 kit but would go with the .50 remember hone also takes .002 off.. If you go with a .25 you may have issues with endgap.

  10. #10
    FYI for a little extra pop on your ski, an impeller and intake grate is a good way to go. Simple, a few extra MPH and they arent gonna send you on a troubleshooting extravaganza all summer

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