service limit on a rebore

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  • Spud's Dad
    • Feb 2026

    #1

    service limit on a rebore

    My GS550m has 0.5 oversized pistons. To calculate the service limits for bore and piston diameters do I simply add 0.5mm to the service limits of standard diameters?
  • Grimly
    Forum Guru
    Past Site Supporter
    Super Site Supporter
    • Sep 2012
    • 5764
    • Ireland

    #2
    I'd go with that - in the absence of reliably sourced figures, it's as good a reference as any. As a guide, look at a manual for a model that contains overbore and ring tolerances for relative figures and see if they go out of kilter with the overbore size; 450, 650, 850, 1000, etc.
    Dave
    '79 GS850GN '80 GS850GT
    Only a dog knows why a motorcyclist sticks his head out of a car window

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    • Nessism
      Forum LongTimer
      GSResource Superstar
      Past Site Supporter
      Super Site Supporter
      • Mar 2006
      • 35790
      • Torrance, CA

      #3
      Measure the piston and bore per the service manual procedure.

      Max piston to bore clearance = .120mm (.0047") (according to the FSM)

      Can't find the reference in the FSM but a good rule of thumb is for there to be no more than .001" out of round or taper in the cylinder.
      Ed

      To measure is to know.

      Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

      Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

      Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

      KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

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