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Cylinder Inside Diameter Measurement; Piston Outside Diameter Measurement; Piston/cylinder Clearance - Kawasaki KLX110 Service Manual

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Cylinder, Piston
Fit a new piston 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 a piston pin snap ring, compress it only enough to
install it no more.
Do not reuse snap rings, as removal weakens and deforms
them. They could fall out and score the cylinder wall.

Cylinder Inside Diameter Measurement

Since there is a difference in cylinder wear in different directions,
take a side to side and a front to back measurement at each of the 3
locations (total of 6 measurements) shown in the figure.
If any of the cylinder inside diameter measurements exceeds the
service limit, the cylinder will have to bored to oversize and then
honed.
Cylinder Inside Diameter
Standard:
52.997
ence between any two measurements
Service Limit:
53.10 mm or 0.05 mm diffeence between any two
measurements
10 mm [A]
60 mm [B]
20 mm [C]

Piston Outside Diameter Measurement

Measure the outside diameter [A] of the piston 7.8 mm [B] up from
the bottom of the piston at a right angle to the direction of the piston
pin.
Piston Outside Diameter
Standard:
52.981
Servie Limit:
52.83 mm
Abnormal wear such as a marked diagonal pattern across the
piston skirt may mean a bent connecting rod or crankshaft.

Piston/Cylinder Clearance

The most accurate way to find the piston clearance is by making sep-
arate piston and cylinder diameter measurements and then computing
the difference between the two values. Measure the piston diameter as
just described, and measure the cylinder diameter at the very bottom
of the cylinder.
Piston/Cylinder Clearance
Standard:
0.010
Whenever the piston or cylinder has been replaced with a new one,
the motorcycle must be broken in the same as with a new machine.
CAUTION
53.009 mm and less than 0.01 mm differ-
52.993 mm
NOTE
0.022 mm
NOTE
ENGINE TOP END 4-29

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