Kawasaki KLV1000 (2004) [135/529] Using a micrometer measure the piston outside diameter at 10 mm 0 in from the piston skirt end if the measurement is less than the limit replace the piston

3-48 ENGINE

CYLINDER BORE

Inspect the cylinder wall for any scratches, nicks or other dam-

age. Measure the cylinder bore diameter at six places.

 Cylinder bore

Standard: 98.000 – 98.015 mm (3.8583 – 3.8589 in)

\ 09900-20508: Cylinder gauge set

PISTON DIAMETER

Using a micrometer, measure the piston outside diameter at

10 mm (0.4 in) from the piston skirt end. If the measurement

is less than the limit, replace the piston.

 Piston diameter

Service Limit: 97.880 mm (3.8535 in)

\ 09900-20204: Micrometer (75 – 100 mm)

PISTON-TO-CYLINDER CLEARANCE

As a result of the previous measurement, if the piston to cylinder

clearance exceeds the following limit, replace both cylinder and

piston.

 Piston to cylinder clearance

Service Limit: 0.12 mm (0.0047 in)

10 mm