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

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Table of Contents
Cylinder, Piston
Piston Ring Groove Width
0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.)
0.80 ∼ 0.82 mm (0.0315 ∼ 0.0323 in.)
Service Limit:
0.90 mm (0.035 in.)
0.90 mm (0.035 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 and 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-
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 and needle bearing.

Piston, Piston Pin, Connecting Rod Inspection

Measure the inside diameter of both piston pin holes in
the piston.
Piston Pin Hole Inside Diameter [A]
13.001 ∼ 13.007 mm (0.5119 ∼ 0.5121 in.)
Service Limit: 13.07 mm (0.5146 in.)
If either piston pin hole inside diameter exceeds the ser-
vice limit, replace the piston.
Measure the diameter of the piston pin.
Piston Pin Diameter [B]
12.995 ∼ 13.000 mm (0.5116 ∼ 0.5118 in.)
Service Limit: 12.96 mm (0.5102 in.)
If the piston pin diameter is less than the service limit at
any point, replace the piston pin.


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