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Piston Wear; Piston/cylinder Clearance; Piston Ring/ring Groove Clearance - Kawasaki ZR-7S Service Manual

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Cylinders and Pistons
ENGINE TOP END 3-35
Piston
Wear
.
Measure the diameter [8] (front-to-back) of each piston 6
mm [A] up from the bottom of the piston.
*If the piston's diameter is smaller than the service limit,
replace the piston.
Piston Diameter
Standard:
65.951 -
65.966 mm (2.5965- 2.5971in.)
Service Limit:
65.81 mm (2.591
in.)
Piston/Cylinder Clearance
.
Subtract the piston diameter from the cylinder bore to ob-
tain the piston/cylinder clearance.
Piston/Cylinder Clearance
Standard:
0.040 - 0.067mm (0.0016- 0.0026
in.)
*
If the piston/cylinder clearance is less than the specified
range, use a smaller piston or increase the cylinder bore
by honing.
* If the piston/cylinder clearance is greater than the speci-
fied range use a larger piston.
*If only a piston is replaced, the clearance may exceed the
standard slightly, but it must not be less than the minimum
limit in order to avoid piston seizure.
Piston Ring/Ring Groove Clearance
.
Visually inspect the piston rings and ring grooves.
*
If the piston rings or ring grooves are deformed or dam-
aged, replace the piston and the piston rings.
.
Place a piston ring in its groove, and using a thickness
gauge [A], measure the piston ring/ring groove clearance
at several locations.
Piston Ring/Ring Groove Clearance
Standard:
Top
Second
0.050 - 0.080 mm (0.0020 - 0.0031 in.)
0.030 - 0.070 mm (0.0012 - 0.0028 in.)
Service Limit:
Top
0.18 mm (0.0071 in.)
Second
0.17 mm (0.0067 in.)
*If the clearance exceeds the service limit, measure the
piston ring thickness and the piston ring groove width to
determine whether to replace the ring and the piston as a
set.

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