1992-1995 Kawasaki 750SX Service Manual, Page 70Get this manual
ENGINE TOP END 5-9
Boring and Honing
When boring and honing cylinder, note the following:
o The are two sizes of oversize pistons availableOversize Piston and Rings Oversize Pistons and Rings 0.5 mm Oversize 1.0 mm Oversize Before boring cylinder, first measure the exact diameter of the oversize piston, and then, according to the standard clearance in the Service Date Section, determine the rebore diameterHowever, if the amount of boring necessary would make the inside diameter grater than 1.0 mm oversize, the cylinder block must be replacedo Cy.linder inside diameter must not vary more than 0.01 mm at any pointo Be wary of measurements taken immediately after boring since the heat affects cylinder diametero In tl"le 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 and the service limit for the piston is the oversize piston original diameter minus 0.15 mmIf the exact figure for the reba red diameter is unknown it can be Iroughly determined by measuring th,e diameter at the base of the cylinder