Specifications of Engine top end (Kawasaki Versys 650, 2007-2025) [Engine and systems: Engine repair]

Item	Standard	Service Limit
Camshafts
Cam Height:
Exhaust	35.343 ∼ 35.457 mm (1.3915 ∼ 1.3959 in.)	35.24 mm (1.387 in.)
Inlet	35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.)	35.74 mm (1.407 in.)
Camshaft Journal, Camshaft	0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.)	0.16 mm (0.0063 in.)
Cap Clearance
Camshaft Journal Diameter	23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.)	23.92 mm (0.942 in.)
Camshaft Bearing Inside Diameter	24.000 ∼ 24.021 mm (0.9449 ∼ 0.9457 in.)	24.08 mm (0.948 in.)
Camshaft Runout	TIR 0.02 mm (0.0008 in.) or less	TIR 0.1 mm (0.004 in.)
Cylinder Head
Cylinder Compression	(Usable Range) 1 226 ∼ 1 844 kPa (12.5 ∼ 18.8 kgf/cm², 178 ∼ 267 psi) at 425 r/min (rpm)	—
Cylinder Head Warp	—	0.05 mm (0.002 in.)
Valves
Valve Clearance:
Exhaust	0.22 ∼ 0.31 mm (0.0087-0.0122 in.)	—
Inlet	0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)	—
Valve Head Thickness:
Exhaust	0.8 mm (0.031 in.)	0.5 mm (0.020 in.)
Inlet	0.5 mm (0.020 in.)	0.25 mm (0.0098 in.)
Valve Stem Bend	TIR 0.01 mm (0.0004 in.) or less	TIR 0.05 mm (0.002 in.)
Valve Stem Diameter:
Exhaust	4.455 ∼ 4.470 mm (0.1754-0.1760 in.)	4.44 mm (0.175 in.)
Inlet	4.475 ∼ 4.490 mm (0.1762-0.1768 in.)	4.46 mm (0.176 in.)
Valve Guide Inside Diameter:
Exhaust	4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)	4.58 mm (0.180 in.)
Inlet	4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)	4.58 mm (0.180 in.)
Valve/Valve Guide Clearance (Wobble Method):
Exhaust	0.07 ∼ 0.14 mm (0.0028 ∼ 0.0055 in.)	0.27 mm (0.0106 in.)
Inlet	0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.)	0.22 mm (0.0087 in.)
Valve Seat Cutting Angle	32°, 45°, 55°, 60°	—
Valve Seating Surface:
Width:
Exhaust	0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.)	—
Inlet	0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)	—
Outside Diameter:
Exhaust	27.6 ∼ 27.8 mm (1.087 ∼ 1.094 in.)	—
Inlet	32.6 ∼ 32.8 mm (1.283 ∼ 1.291 in.)	—
Valve Spring Free Length:
Exhaust	41.9 mm (1.65 in.)	40.3 mm (1.587 in.)
Inlet	41.9 mm (1.65 in.)	40.3 mm (1.587 in.)
Cylinder, Pistons
Cylinder Inside Diameter	82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.)	83.10 mm (3.272 in.)
Piston Diameter	82.969 ∼ 82.984 mm (3.2665 ∼ 3.2671 in.)	82.82 mm (3.261 in.)
Piston/Cylinder Clearance	0.010 ∼ 0.037 mm (0.0004 ∼ 0.0015 in.)	—
Piston Ring/Groove Clearance:
Top	0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)	0.17 mm (0.0067 in.)
Second	0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)	0.16 mm (0.0063 in.)
Piston Ring Groove Width:
Top	0.92 ∼ 0.94 mm (0.0362 ∼ 0.0370 in.)	1.02 mm (0.040 in.)
Second	1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.)	1.11 mm (0.044 in.)
Piston Ring Thickness:
Top	0.87 ∼ 0.89 mm (0.0342 ∼ 0.0350 in.)	0.80 mm (0.032 in.)
Second	0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.)	0.90 mm (0.035 in.)
Piston Ring End Gap:
Top	0.25 ∼ 0.40 mm (0.0098 ∼ 0.0157 in.)	0.7 mm (0.028 in.)
Second	0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.)	0.8 mm (0.031 in.)

Specifications of Engine top end (Kawasaki KLE 650 Versys)