# Cylinder Boring And Honing; Piston Ring, Piston Ring Groove Wear; Piston Ring Groove Width - KAWASAKI VN1600 MEAN STREAK Service Manual

Cylinders, Piston

## Cylinder Boring and Honing

There is an oversize piston available. The oversize piston
requires oversize rings.
Oversize Piston and Rings: 0.5 mm (0.02 in.) oversize
Before boring a cylinder [A], first measure the exact di-
ameter of the oversize piston, and then, according to the
standard clearance in the Specifications, determine the
rebore diameter. However, if the amount of boring nec-
essary would make the inside diameter greater than 0.5
mm (0.02 in.), the cylinder block must be replaced.
Cylinder inside diameter must not vary more than 0.01
mm (0.0004 in.) at any point.
Be wary of measurements taken immediately after boring
since the heat affects cylinder diameter.
In the case of rebored cylinder and oversize piston, the
service limit for the cylinder is the diameter that the cylin-
der was bored to plus 0.1 mm (0.004 in.) and the service
limit for the piston is the oversize piston original diameter
minus 0.15 mm (0.0059 in.). If the exact figure for the re-
bored diameter is unknown, it can be roughly determined
by measuring the diameter at the base of the cylinder.

### Piston Ring, Piston Ring Groove Wear

Check for uneven groove wear by inspecting the ring seat-
ing.
The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
With the piston rings in their grooves, make several mea-
surements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove Clearance
Standard:
Top
0.05 ~ 0.09 mm
(0.00197 ~ 0.00354 in.)
Second
0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in.)
If the piston ring groove clearance is greater than the ser-
vice limit, measure the ring thickness and groove width as
follows to decide whether to replace the rings, the piston
or both.

### Piston Ring Groove Width

Measure the width of the top [A] and second [B] ring
grooves.
Use vernier calipers at several points around the piston.
Piston Ring Groove Width
Standard
Top
1.24 ~ 1.26 mm
(0.048819 ~ 0.049606 in.) (0.05276 in.)
Second
1.22 ~ 1.24 mm
(0.04803 ~ 0.04882 in.)
If the width of any of the two grooves is wider than the
service limit at any point, replace the piston.
Service Limit:
0.19 mm
(0.00748 in.)
0.17 mm
(0.00669 in.)
Service Limit
1.34 mm
1.32 mm
(0.05197 in.)
ENGINE TOP END 5-45