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Piston Ring, Piston Ring Groove Wear Inspection; Piston Ring End Gap Inspection; Cylinder Inside Diameter Measurement - Kawasaki EN500 Vulcan 500 LTD Service Manual

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4-32 ENGINE TOP END
Cylinder, Piston

Piston Ring, Piston Ring Groove Wear Inspection

Check for uneven groove wear by inspecting the ring seat-
ing.
The rings should fit perfectly parallel to the groove sur-
faces. If not, the piston must be replaced.
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
Second
Service Limit:
Top
Second

Piston Ring End Gap Inspection

Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Set it close to the
bottom of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top
Second
Oil
Service Limit:
Top
Second
Oil

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 3 locations (total of 6 measurements)
shown in the figure.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, the cylinder will have to be bored
to oversize and then honed.
[A] 10 mm
[B] 60 mm
[C] 20 mm
Cylinder Inside Diameter
74.000 ∼ 74.012 mm (2.913 ∼ 2.914 in.)
Standard:
Service Limit:
74.11 mm (2.918 in.)
0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)
0.17 mm (0.0067 in.)
0.16 mm (0.0064 in.)
0.2 ∼ 0.35 mm (0.0079 ∼ 0.0138 in.)
0.2 ∼ 0.35 mm (0.0079 ∼ 0.0138 in.)
0.2 ∼ 0.7 mm (0.0079 ∼ 0.0275 in.)
0.7 mm (0.028 in.)
0.7 mm (0.028 in.)
1.0 mm (0.039 in.)

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   Also See for Kawasaki EN500 Vulcan 500 LTD

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Vulcan 500 ltd

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  • Ricardo Paluan Apr 27, 2016 01:22:
    Adquiri recentemen​te uma moto vulcan 500 ano 1995. Tenho o 37 anos e iniciante no mundo motociclis​ta. Entretanto​, em razão só tempo e idade da moto, não tenho o manual do proprietá​rio, sendo este indispens