Question about 2003 kawasaki KX 250

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Bore size I have a 1995 kx 250 is the bore of the cylinder 66.40mm or is that the actual size of the piston and at what size of the cylinder is not acceptable

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The cylinder bore is just that > the bore size of the cylinder. The piston clearance should be 0.0015 to 0.003. Anything more than .005 and the piston is too loose.

Posted on Apr 17, 2009

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Standard bore size mm


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Mar 15, 2014 | 1999 Daewoo Lanos

1 Answer

I got a 2004 ktm 65 the cylinder bore size is 45.33 will a piston size 45.00 work with this need the answer like asap my email is raceday5656@yahoo.com thanks


No, You need to get the specs on that bike,and see what the standard bore is on it. It may be that your standard bore is 45,and the cylinder needs to be bored out to accept a new oversize piston.

Sep 23, 2012 | Motorcycles

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Bad pistions on 94 buick centry 3.1l think engion stamp is g dont know if i have to put just pision in or rod assambly


It's rare that a piston goes bad. So, you need to determine why it failed.
Most times, the cylinder wall is damaged during a piston failure making it impossible to just replace the piston. Check the wall for score marks and out of round condition as well as actual size VS original bore size. (correcting that requires machine work) The new piston must match the cylinder bore as it is now, NOT what it was when manufactured. (same applies to rings).
The old rod can be re-used if it is not bent and providing that the big end (crank end) is still round. Again, the rod needs to be assembled by a machine shop as the wrist-pin is a press-in part.
Most times, you will find that the amount of actual work necessary to replace one piston exceeds what would be necessary to replace the engine in both time, $ and reliability.
If you want to try a replacement though, see if you can get a piston/rod assembly that is still in good condition from a blown junkyard engine, Plasti-gage the bearing and replace if necessary, clean out the ring grooves or replace the rings. Use a hand held cylinder hone and break the glaze on the cylinder walls. If you are careful and everything goes well, it MIGHT work.
Personally I would never replace pistons in an engine without doing all the necessary machine work though.

Aug 22, 2011 | Buick Century Cars & Trucks

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Okay i cant find a used 1993 kawasaki kx 250 cylinder jug and head .all i see is 1992 kx 250 cylinders and head what is the difference. they look alike


You should contact Kustom-kraft.com. They will repair yours. I've sent them 5 so far, and all have come back perfect. $65 for bore/hone.

Jan 15, 2011 | kawasaki KX 250 Motorcycles

1 Answer

I have 2002 dr z 250 can the cylinder be bored out, or do just replace with new.


Yes the cylinder can be bored, BUT, it would be sent to a company in California for the work. The cylinder has a nickel plated surface that will be destroyed by the bore job. After the boring is done they re-plate the cylinder and send back a new oversize piston and rings along with the re-plated cylinder. The cost is around $400. It will take about 3 weeks to get the cylinder back.

A brand new cylinder will cost around $420, piston $48 and rings $35 for a total of just over $500. The time needed will be depending on whether or not your dealer has the parts on hand. Please rate my answer. Thanks.

Aug 24, 2010 | 2002 Suzuki DR-Z 250

1 Answer

Can you bore a sleeved cylinder from a standard 1991 Kawasaki kx 250 or will it need to be re-sleeved? Not sure if the cylinder sleeve is stock. My understanding is that Kawasaki installed factory sleeves...


If you say it is definately sleeved it should be possible to bore it, you normally get one or two oversizes before it needs resleeving. If you are able to buy an over size piston from kawa or wiseco, chances are it can be bored.

Apr 16, 2010 | 2003 kawasaki KX 250

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I have a 01 kaw bayou just put a top end kit in now i have piston slap please help even bought a sleeve for it had some yaho pressed @ bored it not sure if he did it right bore diam is 66.8


if it is piston slap,you will need pull the top off again and measure with a feeler gauge between the piston skirt and the sleeve, should only be a couple of thou

Mar 21, 2010 | 2003 kawasaki KX 250

2 Answers

My cylinder got gouged by the piston. Can I bore


It depends on how deep the gouge is. Having it bored and a new oversized piston may set you back more than a new stock piston and cylinder.

Oct 26, 2009 | 2005 Honda CRF 250 R

2 Answers

We need to order a new piston and rings kit for a 2001 yamaha blaster 200. Not sure how the measurements work. Tha calabrator is reading 66.35 on the piston and the jug reads 66.52. so we are not sure what...


take the measurement of your block.

having a smaller ring will ensure block not being damaged but prone to a Blow-By. a too-tight ring can get your block damaged. so for you to know which size to get regardless of the stock size, tyr to get the block measurement first, then off you go wich ring to get

Jul 12, 2009 | 2003 Yamaha YZ 250

1 Answer

Piston rings


First, be sure they actually do fit the bore. Take a ring and insert it in the bore. push the ring halfway into the bore using the piston. There should be about a 1/32" gap in the ring. Anything more than 1/16" and you need rings the next size up. If the ring won't go into the cylinder because the gap fully closes, the rings need to be a smaller size.

With the correct size rings, put them on the piston. Some pistons have an index pin in the ring groove Fit the gap to the pin. Put the piston mid-stroke and place the cylinder over the top of the piston. Squeeze the rings closed as you gently tap the cylinder downward and over the rings.

Please rate this solution. Thanks garethholleb!

Apr 04, 2009 | Gilera Runner VX 125 Motorcycles

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