2005-2009 Kawasaki Brute Force 650/KVF 650 4x4 Service Manual, Page 148Get this manual
5-40 ENGINE TOP END Cylinder and Piston
Cylinder Boring and Honing
OThere is an oversize piston availableThe oversize piston requires oversize ringsOversize Piston and Rings: 0.5 mm (0.02 in oversize
Before boring cylinder [A], first measure the exact diameter of the oversize piston, and then, according to the standard clearance in the Specifications, determine the rebore diameterHowever, if the amount of boring necessary would make the inside diameter greater than 0.5 mm (0.02 in, the cylinder block must be replacedOCylinder inside diameter must not vary more than 0.01 mm (0.0004 in 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 service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm (0.004 in and the service limit for the piston is the oversize piston original diameter minus 0.15 mm (0.0059 inIf the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinder