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Cylinder Inside Diameter Measurement; Piston Wear Inspection - Kawasaki KLX110 Service Manual

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Cylinder, Piston
If a new piston is used, check piston to cylinder clear-
ance (see Piston/Cylinder Clearance Inspection), and
use new piston rings.
Install the piston so that the "EX" mark [A] on the piston
toward exhaust side.
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 di-
rections, take a side to side and a front to back measure-
ment at each of the three locations (total of six measure-
ments) shown in the figure.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, the cylinder will have to bored to
oversize and then honed.
Cylinder Inside Diameter
52.997 ∼ 53.009 mm (2.0865 ∼ 2.0870
in.) and less than 0.01 mm (0.0004
in.) difference between any two
Service Limit: 53.10 mm (2.0905 in.) or 0.05 mm
(0.002 in.) difference between any two
10 mm (0.39 in.) [A]
60 mm (2.4 in.) [B]
20 mm (0.79 in.) [C]

Piston Wear Inspection

Measure the outside diameter [A] of the piston 3.8 mm
[B] up from the bottom of the piston at a right angle to the
direction of the piston pin.
Piston Diameter
52.969 ∼ 52.981 mm (2.0854 ∼ 2.0859 in.)
Service Limit: 52.82 mm (2.080 in.)
Abnormal wear such as a marked diagonal pattern
across the piston skirt may mean a bent connecting
rod or crankshaft.


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