E-Z-GO Engine - Measure Piston Pin, Piston Pin Hole, and Connecting Rod Wear; Measure Piston Diameter

ENGINE MEASUREMENTS
Page C-13
Kawasaki Engine Shop Rebuild Manual
Measure Piston Pin, Piston Pin Hole, and
Connecting Rod Wear
A. Remove the piston pin.
B.
Measure the outside diameter of the piston pin with a
micrometer at several points.
C. If the outside diameter is less than service limit,
replace the piston pin.
Piston Pin Outside Diameter
Standard: 18.995 ~ 19.000 mm (0.74783 ~ 0.74803 in.)
Service Limit: 18.96 mm (0.7465 in.)
D.
Measure the inside diameter [A] of the piston pin hole
at several points on both sides. Use a dial bore
gauge.
E. If the inside diameter is more than the service limit,
replace the piston.
Piston Pin Hole Inside Diameter
Standard: 19.004 ~ 19.015 mm (0.74819 ~ 0.74862 in.)
Service Limit: 19.08 mm (0.7512 in.)
F.
Measure the inside diameter [A] of the small end of
the connecting rod at several points. Use a dial bore
gauge.
G. If the inside diameter is more than the service limit,
replace the connecting rod.
Connecting Rod Small End Inside Diameter
Standard: 19.010 ~ 19.021 mm (0.74842 ~ 0.74886 in.)
Service Limit: 19.06 mm (0.7504 in.)
Measure Piston Diameter
A.
Measure the outside diameter [A] of the piston 18 mm
(0.71 in.) up [B] from the bottom of the piston at a
right angle to the direction of the piston pin hole.
B. If the measurement is less than the service limit,
replace the piston.
Piston Diameter
Standard: 81.935 ~ 81.955 mm (3.2258 ~ 3.2266 in.)
Service Limit: 81.79 mm (3.220 in.)