2003 Kawasaki JetSki 800 SX-R Factory service manual, Page 95Get this manual
ENGINE TOP END 5-11 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 [C] 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
Inspect the inside of the cylinder for scratches and abnormal wearIf the cylinder is damaged or badly worn, replace it with new oneSince there is difference in cylinder wear in different directions, take side-to-side and front-to-back measurement at each of the 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 bored oversize and then honedCylinder Inside Diameter 82.000 82.015 mrn (3.228 3.229 in Standard: and less than 0.01 mm (0.004 in difference between any two measurements 82.10 mm (3.232 in, or more than Service Limit: 0.05 mm (0.002 in difference between any two measurements