Kawasaki WORKHORSE 250 (2003) [97/322] Cylinder inside diameter
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Kawasaki WORKHORSE 250 (2003) [97/322] Cylinder inside diameter

Kawasaki WORKHORSE 250 (2003) [97/322] Cylinder inside diameter
ENGINE TOP END 4-33
Cylinder and Piston
•
Install the second ring [A] so that the “RN” mark [B] faces
up.
•
Install the top ring [C] so that the “R” mark [D] faces up.
•
Install the piston pin.
○
Oil the piston pin lightly and slide it through the side of the
piston without a snap ring.
○
Hold the piston in position over the connecting rod, with
the arrow [A] pointing forward, and slide the piston pin the
rest of the way through the connecting rod and piston.
•
Fit a new piston pin snap ring into the side of the piston
so that the ring opening does not coincide with the slit of
the piston pin hole.
Cylinder/Piston Wear
•
Since there is a difference in cylinder wear in different di-
rection, take a side-to-side and a front-to-back m easure-
ment at each of the 3 locations (total of 6 m easurements)
showninthefigure.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, replace the cylinder.
20 mm (0.79 in.) [A]
40 mm (1.57 in.) [B]
10 mm (0.39 in.) [C]
Cylinder Inside Diameter
Standard: 68.995 ∼ 69.007 mm (2.7163 ∼ 2.7168 in.),
and less than 0.01 mm (0.0004 in.)
difference between any two
measurements
Service Lim it : 69.10 m m (2.720 in.), or more than
0.05 mm (0.0020 in.) differen ce bet we e n
any two meas urements
•
M
easure the piston diameter [A] of each piston 5 mm
(0.20 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
Piston Diameter
Standard:
68
.960 ∼ 68.975 mm
(2.7150 ∼ 2.7155 in.)
Service Limit: 68.81 mm (2.709 in.)
If the piston diameter is l ess than the service limit, replace
it.

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