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Piston, Piston Pin, Connecting Rod Wear Inspection; Piston, Piston Pin, Connecting Rod Inspection - Kawasaki KLX110 Service Manual

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Cylinder, Piston
If the clearance exceeds the service limit, remove the piston rings,
and measure the thickness of the piston rings and the width of the
ring grooves. If the ring has worn down to less than the service limit,
replace the ring, if the groove width exceeds the service limit replace
the piston.
These tables apply to oversize pistons and rings as well as standard
and pistons and rings.

Piston, Piston Pin, Connecting Rod Wear Inspection

Visually inspect the snap rings [A] are fitted in place.
If the ring shows weakness or deformation, replace the ring. Also if
the pin hole groove shows excessive wear, replace the piston.
Visually inspect the piston pin hole and connecting rod small end
hole.
If the piston pin hole shows uneven wear, replace the piston.
If the rod small end hole shows uneven wear, replace the rod, or
crankshaft assembly.
Visually inspect the outer surface of the piston pin [B].
If the pin shows color change or stepped wear, replace the pin and
needle bearing.

Piston, Piston Pin, Connecting Rod Inspection

Measure the inside diameter of both piston pin holes in the piston.
Piston Pin Hole Inside Diameter [A]
Standard:
Service Limit:
If either piston pin hole inside diameter exceeds the service limit,
replace the piston.
Measure the diameter of the piston pin.
Piston Pin Diameter [B]
Standard:
Service Limit:
If the piston pin diameter is less than the service limit at any point,
replace the piston pin.
Measure the inside diameter[A] of the connecting rod small end.
Connecting Rod Small End Inside Diameter
Standard:
Service limit
If the inside diameter exceeds the service limit, replace the connecting
rod.
NOTE
13.001
13.007 mm
13.07 mm
12.995
13.000 mm
12.96 mm
13.003
13014 mm
13.05 mm
ENGINE TOP END 4-31

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