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

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4-38 ENGINE TOP END
Cylinder, Piston
Piston Ring/Groove Clearance
Standard:
0.020 ∼ 0.060 mm (0.0008 ∼ 0.0024 in.)
Top
0.010 ∼ 0.050 mm (0.0004 ∼ 0.0020 in.)
Second
Service Limit:
Top
0.16 mm (0.0063 in.)
Second
0.15 mm (0.0059 in.)
Piston Ring Thickness
Standard:
0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Top
0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Second
Service Limit:
Top
0.70 mm (0.0276 in.)
Second
0.70 mm (0.0276 in.)
Piston Ring Groove Width
Standard:
0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.)
Top
0.80 ∼ 0.82 mm (0.0315 ∼ 0.0323 in.)
Second
Service Limit:
Top
0.91 mm (0.0358 in.)
Second
0.90 mm (0.0354 in.)
If the clearance exceeds the service limit, remove the pis-
ton 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 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 pis-
ton.
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.
NOTE

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Klx110l

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