E-Z-GO Engine, Shop Rebuild Manual

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ENGINE MEASUREMENTS
Page C-12
Kawasaki Engine Shop Rebuild Manual
E. If the piston ring/groove clearance is greater than the
specified value, replace the piston.
Piston Ring/Groove Clearance
Standard:
Top, Second 0.04 ~ 0.08 mm (0.002 ~ 0.003 in.)
Service Limit:
Top, Second 0.18 mm (0.0071 in.)
The oil ring is a three-piece assembled ring. It is difficult to
measure the ring groove clearance and thickness; visually
inspect only.
F.
Measure the piston ring thickness [A].
G. Use a micrometer to measure at several points
around the rings.
H. If any of the measurements are less than the service
limit, replace the entire set of rings.
Piston Ring Thickness
Standard:
Top, Second 1.47 ~ 1.49 mm (0.0579 ~ 0.0587 in.)
Service Limit:
Top, Second 1.40 mm (0.0551 in.)
When using new rings in a used piston, check for uneven
groove wear. The rings should fit perfectly parallel to the groove
sides. If not, replace the piston.
Measure Piston Ring End Gap
A. Remove the piston rings.
B. Push each ring (one at a time) into the cylinder bore
to a point close to the bottom of the cylinder bore.
C. Use the piston to push it in to be sure it is square.
D.
Measure the gap [A] between the ends of the ring [B]
with a thickness gauge.
E. If the end gap of any ring is greater than the service
limit, replace the entire set of rings.
Piston Ring End Gap
Standard:
Top 0.15 ~ 0.40 mm (0.0059 ~ 0.016 in.)
Second 0.23 ~ 0.48 mm (0.0091 ~ 0.019 in.)
Oil 0.25 ~ 0.75 mm (0.0098 ~ 0.030 in.)
Service Limit:
Top 0.7 mm (0.03 in.)
Second 0.8 mm (0.03 in.)
Oil 1.0 mm (0.039 in.)