Kawasaki KX250F (2004) [158/357] Http manuals magnamaniac com
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Kawasaki KX250F (2004) [158/357] Http manuals magnamaniac com

Kawasaki KX250F (2004) [158/357] Http manuals magnamaniac com
ENGINE TOP END 5-33
Cylinder and Piston
Piston Ring Thickness
•
Measure the thickness at several points around ring with
amicrometer.
Piston Ring Thickness (Top)
Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Service Limit: 0.70 mm (0.0276 in.)
If any of the measurements is less than the service limit
on either of the rings, replace the rings as a set.
NOTE
○
When using new rings in a used piston, check for un-
even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
Piston Ring End Gap Measurement
•
Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Place the piston
ring close to the bottom of the cylinder, where cylinder
wear is m inimal
•
Measure the gap [B] between the ends of the ring using
a thickness gauge.
If the ring end gap exceeds the service limit, replace the
ring.
Piston Ring End G ap
Standard: Service Limit:
Top 0.15 ∼ 0.25 mm
0.55 mm (0.0217in.)
(0.0059 ∼ 0.0098 in.)
Oil 0.20 ∼ 0.70 mm 1.0 mm (0.0394 in.)
(0.0079 ∼ 0.0276 in.)
Piston, Piston Pin, Connecting Rod Wear Inspection
•
Visually inspect the snap ring [A] still 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.
•
Measure the diameter of the piston pin [B] w ith a microm-
eter.
If the piston pin diameter is less than the service limit at
any point, replace the piston pin.
•
Using a cylinder gauge, measure the diameter of both of
piston pin holes [C] in the piston and the inside diameter
of the connecting rod small end [D].
If either piston pin hole diameter exceeds the service limit,
replace the piston.
If the connecting rod small end inside diameter exceeds
the service limit, replace the connecting rod.
Piston Pin Diameter
Standard: 15.992 ∼15.997 mm (0.6296 ∼ 0.6298 in.)
Service Limit: 15.96 mm (0.628 in.)
Piston Pin Hole Diameter
Standard: 16.004 ∼ 16.010 mm (0.6301 ∼ 0.6303 in.)
Service Limit: 16.07 mm (0.633 in.)
Small End Inside Diameter
Standard: 16.010 ∼ 16.018 mm (0.6303 ∼ 0.6306 in.)
Service Limit: 16.05 mm (0.632 in.)

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