ENGINE BOTTOM END DISASSEMBLY
Page B-5
Kawasaki Engine Shop Rebuild Manual
Item Standard Service Limit
Cylinder and Piston
Piston Ring/Groove Clearance:
Top, Second 0.04 ~ 0.08 mm 0.18 mm
Piston Ring Thickness: (0.002 ~ 0.003 in.) (0.0071 in.)
Top, Second 1.47 ~ 1.49 mm 1.40 mm
(0.0579 ~ 0.0587 in.) (0.0551 in.)
Piston Ring End Gap:
Top 0.15 ~ 0.40 mm 0.7 mm
(0.0059 ~ 0.016 in.) (0.03 in.)
Second 0.23 ~ 0.48 mm 0.8 mm
(0.0091 ~ 0.019 in.) (0.03 in.)
Oil 0.25 ~ 0.75 mm 1.0 mm
(0.0098 ~ 0.030 in.) (0.039 in.)
Piston Pin Outside Diameter 18.995 ~ 19.000 mm 18.96 mm
(0.74783 ~ 0.74803 in.) (0.7465 in.)
Piston Pin Hole Inside Diameter 19.004 ~ 19.015 mm 19.08 mm
(0.74819 ~ 0.74862 in.) (0.7512 in.)
Connecting Rod Small End Inside Diameter 19.010 ~ 19.021 mm 19.06 mm
(0.74842 ~ 0.74886 in.) (0.7504 in.)
Piston Diameter 81.935 ~ 81.955 mm 81.79 mm
(3.2258 ~ 3.2266 in.) (3.220 in.)
Cylinder Inside Diameter 81.97 ~ 81.99 mm 82.10 mm
(3.227 ~ 3.228 in.) (3.232 in.)
Cylinder Bore Out-Round – – – 0.05 mm
– – – (0.002 in.)
Piston/Cylinder Clearance 0.015 ~ 0.055 mm – – –
(0.00059 ~ 0.0022 in.) – – –
Balancer Shaft
Balancer Shaft Journal Diameter 31.959 ~ 31.975 mm 31.935 mm
(1.2582 ~ 1.2589 in.) (1.2573 in.)
Balancer Shaft Bearing Inside Diameter:
Crankcase Side 32.000 ~ 32.016 mm 32.06 mm
(1.2598 ~ 1.2605 in.) (1.262 in.)
Crankcase Cover Side 32.000 ~ 32.016 mm 32.06 mm
(1.2598 ~ 1.2605 in.) (1.262 in.)
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