103
Disassembly/Inspection and Service
24 690 06 Rev. P KohlerEngines.com
Piston Style B
1. Cylinder bore must be de-glazed before service ring
sets are used.
2. If cylinder bore does not need re-boring and if old
piston is within wear limits and free of score or scuff
marks, old piston may be reused.
3. Remove old rings and clean up grooves. Never
reuse old rings.
4. Before installing new rings on piston, place top 2
rings, each in turn, in its running area in cylinder
bore and check end gap.
80 mm bore engines: Top compression ring end gap
clearance is 0.100/0.279 mm (0.0039/0.0110 in.) for
a new bore, or 0.490 mm (0.0192 in.) for a used
bore. Middle compression ring end gap is
1.400/1.679 mm (0.0551/0.0661 in.) for a new bore,
or 1.941 mm (0.0764 in.) for a used bore.
83 mm bore engines: Top compression ring end gap
clearance is 0.189/0.277 mm (0.0074/0.0109 in.) for
a new bore, or 0.531 mm (0.0209 in.) for a used
bore. Middle compression ring end gap is
1.519/1.797 mm (0.0598/0.0708 in.) for a new bore,
or 2.051 mm (0.0808 in.) for a used bore.
5. After installing new compression (top and middle)
rings on piston, make sure top compression ring-to-
groove side clearance and is 0.030/0.070 mm
(0.0010/0.0026 in.) and middle compression ring-to-
groove side clearance 0.030/0.070 mm
(0.0010/0.0026 in.). If side clearance is greater than
specifi ed, a new piston must be used.
Install New Piston Rings
Piston Ring Orientation
10°
10°
F
A
B
C
D
E
A
Top Oil Ring Rail
Gap
B
Bottom Oil Ring Rail
Gap
C
Intermediate Ring
Gap
D
Oil Ring Expander
Gap
E Top Ring Gap F FLY Stamp
NOTE: Rings must be installed correctly. Ring
installation instructions are usually included with
new ring sets. Follow instructions carefully. Use
a piston ring expander to install rings. Install
bottom (oil control) ring fi rst and top
compression ring last.
To install new piston rings, proceed as follows:
1. Oil control ring (bottom groove): Install expander and
then rails. Make sure ends of expander are not
overlapped.
2. Middle compression ring (center groove): Install
center ring using a piston ring installation tool. Make
sure identifi cation mark is up or colored dye stripe
(if contained), is to left of end gap.
3. Top compression ring (top groove): Install top ring
using a piston ring expander. Make sure
identifi cation mark is up or colored dye stripe
(if contained), is to left of end gap.
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