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Piston/cylinder Clearance; Piston Ring, Piston Ring Groove Inspection; Piston Ring End Gap Inspection - Kawasaki KX125 1990 Service Manual

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Piston/Cylinder
Clearance
The piston-to-cylinder clea ra nce is measured
whenever
a
piston
or cylinder is replaced with a new
one. The standard
piston-to-cylinder
clearance
must
be
adhered to whenever the
cylinder
is
replaced.
If only a piston is re
placed,
the clearance may
ex-
ceed the standard
slightly.
But it must not be
less
than the minimum, in order to avoid piston
seizure.
The most accurate
way
to find the piston clearance
is by making separate 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.
Plstonl~
Clearance
10(125:
KX250:
0 .071
-
0 .091
mm
0 .059
-
0
.079 mm
Piston
Ring,
Piston
Ring
Groove Inspection
Visually inspect the
piston
rings and the piston
ring
grooves.
*
If the rings are wom unevenly or
damaged.
they
must be
replaced.
*
If
the piston ring grooves are wom
unevenly
or
damaged, the piston must be replaced and fitted with
neYI
rings.
Check
for
uneven groove
wear
by inspecting the ring
seating.
*
The rings
should
fit
perfectly
parallel
to the groove
surfaces.
If
not,
the
piston
must be
replaced.
With the pistoo ring
in
its groove. make several
measurements
with
a thickness gauge to determine
piston ringlgroove clearance.
*If
the
clearance exceeds the service limit, measure
the
th
ickness of the piston
ring.
*
If
the ring has wom
down
to less t han the service
limit, replace the ring; if the groove
width
exceeds
the service limit, replace the
piston.
Piston
Ring/Groove
Clearance
Standard:
0.04
-
0 .08
mm
Service
Limit:
0.18
mm
Piston
Ring
Thickness
Standard:
KX125:
0 .77
-
0.79
mm
KX250:
0 .97
-
0.99
mm
Service
Umit:
KX125:
0.7
mm
KX250:
0 .9
mm
Piston Ring Groove Width
Standard:
KX125:
0.83-0.85 mm
KX250:
1.03
-
1.05
mm
Service
Umit:
KX125:
0.93
mm
KX260:
1.
10
mm
ENGINE TOP
END
4-
1 5
A.
Thickness Gauge
Piston Ring End Gap Inspection
Place the
piston
ring inside the cylinder, using the
piston to locate the ring SQuarely
in
place.
Set it close to the bottom of the cylinder. where cyl-
inder wear
is
low.
Measure the gap between the ends of the ring with
a thickness
gauge.
*
If the gap
is
wider
t han the
service
limit. the ring is
overworn
and must be
replaced.
Piston
Ring
End
Gap
Standard:
0
.15-
0
.35
mm
Service
Umtt:
0
.70
mm
Ring
End
Gap Measurement
o
,
00
1.
Piston Ring
3.
Thickness Gauge
2.
Cylinder Block

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