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Piston Diameter Measurement; Piston/cylinder Clearance; Piston Ring, Piston Ring Groove Inspection - Kawasaki KDX200 Service Manual

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4-10 ENGINE TOP END
Piston Diameter Measurement
.
Measure the outside
diameter
of the piston 16 mm
[A]
up from the
bottom of the piston at a
right
angle to the direction of the piston
pin.
*
t,
the
m
easurement is under
t
he service
limit,
replace the piston
.
PIston
DIameter
Standard:
65.942 -
65.957 mm
Service
Limit.:
65.8 mm
Piston/Cylinder Clearance
The piston -Ie -cylinder clearance is measured whenever a piston or
cylinder is replaced
with
a new
one.
The standard piston-Io-cylinder
clearance must be adhered to whenever the cylinder is
replaced.
If only a piston is
replaced,
the clearance may exceed the standard
slightly.
But
it
must not be less than the minimum in order to avoid
piston seizure.
The most accurate way to find
t
he piston clearance is by making
separate piston
and
cylinder diameter measurements and then compu
t-
ing
t
he difference between the two values. Measure the piston diameter
as just
described,
and measure the cylinder diameter at
t
he very bonom
of
t
he
cylinder.
Piston /Cylinder Clearance
Standard:
0.079
-
0.089 m
m
NOTE
o
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.
Piston Ring. Piston Ring Groove Inspection
.
Visually inspect the piston rings and the piston ring
grooves.
*
If the ri ngs are worn unevenly or
damaged,
they must be
replaced.
*
If
t
he piston ring grooves are worn unevenly or damaged, the pis ton
must
be
replaced and fitted with new rings .
Check for uneven groove wear by inspecting
t
he ring
seat
ing
.
*The rings
should f
it perfectly parallel to the groove surfaces. If
not,
the
piston must be replaced .
With the pis ton ring in its groove, make several
m
easurements with a
thickness gauge [A] to determine piston ring/groove clearance.
*
"
t
he clearance exceeds
t
he service
limit,
measure the thickness of the
piston
ring.
*
If the ring has worn down to less than the service limit replace
t
he ring;
if the groove width exceeds the service
limit,
replace the
piston.
Piston
Ring/
Groove Clearance
Standard
To.
Second
- - -
(keystone)
0.025
-
0.065 mm
Piston Ring
Thickness
Standard
To.
Second
1.17
-
1.19
mm
1.17
-
1.19
mm
Piston Ring Groove Width
Standard
To.
s.c.nd
- - -
(keystone)
1.215
-
1.235
mm
Service Limit:
0.16
mm
Serv
ice Limit:
1.1 mm
1.1
mm
Sel"llce
Limit:
1.31
mm
a
/u
..If
j0
/

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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