OS 0.75 Piston Kit - Kawasaki KLF 250 Bayou 2003 To 2011
OS 0.75 Piston Kit - Kawasaki KLF 250 Bayou 2003 To 2011 is backordered and will ship as soon as it is back in stock.
Delivery and Shipping info
Delivery and Shipping info
- Standard delivery (2-4 working days) - £4.99 on eligible UK mainland orders under £50.
- Express delivery - £6.99 on eligible UK mainland orders placed before 2pm.
- Large equipment including international orders are subject to different delivery rates and timescales.
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OS 0.75 Piston Kit - Kawasaki KLF 250 Bayou 2003 To 2011
OS 0.75 Piston Kit - Kawasaki KLF 250 Bayou 2003 To 2011 is backordered and will ship as soon as it is back in stock.
OS 0.75 oversize piston kit for the 228cc Bayou ATV family (2003 - 2011) restores peak compression and power after top-end wear. The kit features a 69.75 mm bore (0.75 mm oversize) and comes complete with a piston, rings, wrist pin and circlips for a ready-to-install rebuild. Designed to deliver factory-like reliability in off-road conditions, this top-end refresh helps restore lost performance and smooth, dependable power across the full 2003 - 2011 model span.
With MOS2-coated skirt technology and a cast aluminum alloy piston, this aftermarket replacement reduces friction, improves heat resistance, and promotes longer engine life under harsh trail, farm, or job-site duty cycles. Because it mirrors OEM-style dimensions, it installs cleanly without modifying the engine, delivering durable performance when you need to trust your ATV for demanding work or rough-terrain rides. This kit is a reliable choice for riders who demand restoring power and consistency without the OEM price tag.
What's Included
This kit includes the essential components for a proper top-end refresh.
- Piston
- Rings
- Wrist Pin
- Circlips
Related parts such as gaskets or seals are not included.
OEM & Aftermarket Cross-Reference Information
| Part Number | Brand / Type | Cross-Reference Notes |
|---|---|---|
| 13001-1654 | Kawasaki OEM | Standard bore piston reference |
| 13001-1663 | Kawasaki OEM | Standard bore piston reference |
| 13002-1004 | Kawasaki OEM | Piston pin |
| 13008-1209 | Kawasaki OEM | Piston ring set |
| 92033-1161 | Kawasaki OEM | Circlips |
Fitment
| Manufacturer | Models / Series | Years / Details |
|---|---|---|
| Kawasaki | KLF250 Bayou | A1 (2003) - 2003 Bayou 250 (KLF250-A1) |
| Kawasaki | KLF250 Bayou | A2 (2004) - 2004 Bayou 250 (KLF250-A2) |
| Kawasaki | KLF250 Bayou | A3 (2005) - 2005 Bayou 250 (KLF250-A3) |
| Kawasaki | KLF250 Bayou | A6F (2006) - 2006 Bayou 250 (KLF250A6F) |
| Kawasaki | KLF250 Bayou | A7F (2007) - 2007 Bayou 250 (KLF250A7F) |
| Kawasaki | KLF250 Bayou | A8F (2008) - 2008 Bayou 250 (KLF250A8F) |
| Kawasaki | KLF250 Bayou | A9F (2009) - 2009 Bayou 250 (KLF250A9F) |
| Kawasaki | KLF250 Bayou | AAF (2010) - 2010 Bayou 250 (KLF250AAF) |
| Kawasaki | KLF250 Bayou | ABF (2011) - 2011 Bayou 250 (KLF250ABF) |
Specifications
| Attribute | Details |
|---|---|
| OEM Reference Part Numbers | 13001-1654, 13001-1663, 13002-1004, 13008-1209, 92033-1161 |
| Type | Piston Kit OS 0.75 oversize (69.75 mm bore) with piston, rings, wrist pin and circlips |
| Manufacturer | Aftermarket Replacement |
| Application | Kawasaki KLF250 Bayou (2003 - 2011), 228cc air-cooled four-stroke single |
| Material | Cast aluminum alloy with MOS2-coated skirt |
| Bore Size | 69.75 mm |
| Oversize | +0.75 mm |
| Stroke | 61 mm |
| Displacement | 228 cc |
| Engine Type | Air-Cooled 4-Stroke SOHC Single Cylinder |
| Compression Ratio | 8.9:1 |
| Carburetor | Mikuni VM24SS |
| Starting | Electric and Recoil |
| Kit Contents | Piston, Rings, Wrist Pin, Circlips |
Installation Notes
- Pre-Check Bore: Confirm cylinder bore is 69.75 mm before installation; any out-of-tolerance wear may require honing or re-boring as per service manual.
- Rings & Gaps: Check top and second ring end gaps according to the service manual; replace if out of specification to ensure proper sealing.
- Lubrication: Apply light engine assembly lube to the piston skirts and rings during installation to prevent dry starts.
- Wrist Pin & Circlips: Install wrist pin with proper end clearance and seat circlips securely in grooves; verify with a small twist to ensure they won’t back out during operation.
- Orientation & Clearances: Align piston orientation marks as indicated by OEM drawings; verify piston-to-wall clearance with feeler gauges if required by service manual.
- Clean Assembly: Thoroughly clean the cylinder, head and oil passages; remove all debris to avoid scoring or oil starvation on first startup.
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