1987-2004 Kawasaki Mojave KSF250 Service Manual, Page 72Get this manual
ENGINE TOP END Cylinder Boring, Honing
When boring and honing cylinder, note the following: oThere are two sizes of oversize pistons availableOversize pistons require oversize ringsOversize Pistons and Rings 0.5 mm 'Oversize 1.0mm Oversize OBefore boring cylinder, first measure the exact diameter of the oversize piston, and then, according to the standard clearance (see Specifications in this chapter), determine the rebore diameterHowever, if the amount of boring necessary would make the inside diameter greater than 1.0 mm oversize, the cylinder must be replacedoCylinder inside diameter must not vary more than 0.01 mm at any pointOBe wary of measurements taken immediately after boring since the heat affects cylinder diameteroln the case of rebored cylinder and oversize piston, the limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm and the service limit for the piston is the oversize piston original diameter minus 0.15 mmIf the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinderEnd Gap Measurement Piston Ring