2005-2009 Kawasaki Brute Force 650/KVF 650 4x4 Service Manual, Page 147Get this manual
ENGINE TOP END 5-39 Cylinder and Piston
Install: Cylinder Clamp [A] (rear only) Tighten :
TorqueCylinder Bolts [B]: 9.8 N'm (1.0 kgf'm, 87 in'lb)
Install: Chain Guide [C] Oil Pipe [0]
Cylinder Wear
Since there is difference in cylinder wear in different directions, take side-to-side and front-to-back measurement at each of the three locations (total of six measurements) shown in the figureIf any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder10 mm (0.4 in [A] 60 mm (2.4 in [B] 20 mm (0.8 in [C]
Cylinder Inside Diameter Standard: 79.99480.006 mm (3.14943.1498 in, and less than 0.01 mm (0.0004 in difference between any two measurementsService Limit: 80.09 mm (3.153 in, or more than 0.05 mm (0.0020 in difference between any two measurements
Piston Wear
Measure the outside diameter [A] of each piston mm (0.20 in [B] up from the bottom of the piston at right angle to the direction of the piston pinIf the measurement is under service limit, replace the piston Piston Diameter Standard: Service Limit: 79.949 -79.964 mm (3.14763.1482 in 79.80 mm (3.142 in