2003 Kawasaki 1100 STX D.I. Jet Ski Factory Service Manual, Page 139Get this manual
6-10 ENGINE TOP END Engine Top End
Cylinder Head Warp Inspection
Lay straightedge [A] across the lower surface of the head [B] at several different points, and measure warp by inserting thickness
gauge between the straightedge and the headIf warp exceeds the service limit, repair the mating surfaceReplace the cylinder head if the mating surface is badly damagedCylinder Head Warp Service Limit: 0.05 mm (0.002 in
Cylinder Wear Inspection
scratches and Inspect the inside of the cylinder forworn, replace it abnormal wearIf the cylinder is damaged or badly with new onewear in different directions, Sincea there is difference in cylinder measurement at each of the take side-to-side and front-to-back locations (total of measurements) shown in the figure[A] 10 mm (0.39 in [B] 80 mm (3.15 in [C] 35 mm (1.38 in
If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder will have to be replaced with new oneCylinder Inside Diameter Standard: 80.00080.015 mm (3.14963.1502 in and less than 0.01 mm (0.0004 in difference between any two measurements Service Limit: 80.10 mm (3.154 in, or more than 0.05 mm (0.002 in difference between any two measurements