Kawasaki J300 - Service manual > Piston Ring, Piston Ring Groove Wear Inspection

Engine Top End / Cylinder, Piston / Piston Ring, Piston Ring Groove Wear Inspection

Cylinder, Piston

Piston Ring/Groove Clearance
 Standard:
  Top 0.015 - 0.055 mm (0.0006 - 0.0022 in.)
  Second 0.015 - 0.055 mm (0.0006 - 0.0022 in.)
 Service Limit:
  Top 0.13 mm (0.0051 in.)
  Second 0.13 mm (0.0051 in.)

Piston Ring Groove Width Inspection

Piston Ring Groove Width
 Standard:
  Top [A] 1.00 - 1.02 mm (0.039 - 0.040 in.)
  Second [B] 1.00 - 1.02 mm (0.039 - 0.040 in.)
 Service Limit:
  Top 1.1 mm (0.043 in.)
  Second 1.1 mm (0.043 in.)

Cylinder, Piston

If the width of any of the two grooves is wider than the service limit at any point, replace the piston.

Piston Ring Thickness Inspection

Piston Ring Thickness
 Standard:
  Top [A] 0.97 - 0.99 mm (0.038 - 0.039 in.)
  Second [B] 0.97 - 0.99 mm (0.038 - 0.039 in.)
 Service Limit:
  Top 0.92 mm (0.036 in.)
  Second 0.92 mm (0.036 in.)

Cylinder, Piston

If any of the measurements is less than the service limit on either of the rings, replace all the rings.

NOTE

Piston Ring End Gap Inspection

Piston Ring End Gap
 Standard:
  Top 0.10 - 0.25 mm (0.004 - 0.010 in.)
  Second 0.10 - 0.25 mm (0.004 - 0.010 in.)
  Oil 0.20 - 0.70 mm (0.008 - 0.028 in.)
 Service Limit:
  Top 0.50 mm (0.020 in.)
  Second 0.50 mm (0.020 in.)
  Oil 1.0 mm (0.04 in.)

Cylinder, Piston

If the end gap of either ring is greater than the service limit, replace all the rings.

Piston, Piston Pin, Connecting Rod Wear Inspection

Piston Pin Diameter
 Standard: 14.994 - 15.000 mm (0.59031 - 0.59055 in.)
 Service Limit: 14.96 mm (0.5890 in.)

Cylinder, Piston

If the piston pin diameter is less than the service limit at any point, replace the piston pin.

Piston Pin Hole Diameter
 Standard: 15.002 - 15.008 mm (0.59062 - 0.59086 in.)
 Service Limit: 15.04 mm (0.5921 in.)

Connecting Rod Small End Inside Diameter
 Standard: 15.016 - 15.034 mm (0.59118 - 0.59189 in.)
 Service Limit: 15.06 mm (0.5929 in.)

Cylinder, Piston

If either piston pin hole diameter exceeds the service limit, replace the piston.

If the pin hole groove shows excessive wear, replace the piston.

If the connecting rod small end inside diameter exceeds the service limit, replace the connecting rod.

Cylinder, Piston

See also:

 Kawasaki J300 - Service manual > Piston Installation

Apply molybdenum disulfide oil solution to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the expander and one below it. Spread the rail with your thumbs, but only enough to fit the rail over the piston. Release the rail into the bottom piston ring groove.

 Kawasaki J300 - Service manual > Intake Manifold, Muffler

Intake Manifold Intake Manifold Removal Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Fuel Injector (see Fuel Injector Removal in the Fuel System (DFI) chapter) Disconnect the water temperature sensor connector [A]. Clear the main harness from the clamp [B]. Remove: Intake Manifold Nuts [A] Intake Manifold [B] If necessary, remove the insulator [A].