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Piston, Piston Pin, Connecting Rod Wear; Piston Ring End Gap (top, Second) - Kawasaki KZ400 Service Manual

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Table of Contents
174 MAINTENANCE-ENGINE
A.
Piston Ring
B. Thickness Gauge
Table H 2 9
Piston RingIGroove Clearance
I
I
Service Limit
1
I
Top and 2nd
1
0.1 5 mm
I
Table H 3 0
Piston Ring Thickness
I
I
Service Limit
1
I
Oil
1
2.60 mm
When new rings are being fitted into a used piston,
Table H 3 1
Piston Ring Groove Width
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.
Top and 2nd
Piston ring end gap (top, second)
Place the piston ring inside the cylinder, using the
piston to locate the ring squarely in place. Set i t close
to the bottom of the cylinder, where cylinder wear i s
low.
Measure the gap between the ends o f the ring
with a thickness gauge.
If
the gap is wider than the
service limit, the ring is overworn and must be replaced.
Service Limit
1.33 mm
A. Piston Ring
C. Thickness Gauge
B. Cylinder Block
Table H 3 2
Ring End Gap
I
I
ServiceLimit
I
1
Top and 2nd
1
0.7
mm
I
Piston, piston pin, connecting rod wear
Measure the diameter of the piston pin with a
micrometer, and measure the inside diameter o f both
piston pin holes in the piston.
I f the piston pin di-
ameter i s less than the service limit at any point, replace
the piston pin.
I f either piston pin hole diameter ex-
ceeds the service limit, replace the piston.
A. Piston
6 .
Piston Pin
Measure the inside diameter of the connecting rod
small end.
I f the diameter exceeds the service limit,
replace the connecting rod.
A. Connecting Rod
Table H33
Piston Pin, Pin Hole, Small End Diameter
I
I
Small End
1
14.05 mm
I
-
-
NOTE: When
a
new piston or pin is used, also check
that piston-to-pin clearance is 0.005
-
0.01 6 mm, and
that pin to small end clearance i s within 0.003 -0.019
mm.

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This manual is also suitable for:

Kz500Kz550

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