Measuring the Ring Gap
'83-'86 0.20-0.40 mm or 0.008" - 0.016" (new) Service limit 0.07 mm or 0.028"
'87 -'04 0.15-0.35 mm or 0.006" to 0.014 (new) Service limit is also 0.7mm or 0.028"
Put the ring in the cylinder and use the piston to push it down about 1/2 inch from the top evenly spaced.
( Start the ring in the cyl by hand & then use the top of the piston to push the ring where you want it in the bore. This should have gotten you pretty close to having the ring squared up in the cyl.)
Now use a feeler gauge to measure the width of the ring gap.
This info is from the Clymer pg. 174 table 6
If you have to open up the gap, a small ignition file and patience are in order, work slowly. You don't want to chip any edges of the area your filing. (most of the rings have coating and will Chip if you push too hard with the file or stone)
Squeeze the gap closed and make sure the ring faces meet squarely.
I take emery cloth and lightly run around the rings edges and piston groove to remove any possible burrs from the cutting/machining process. You're not trying to sand the down the corners, so easy does it.
Here is a link to a great write up with help from Mr. Do or Die, ( DoorDie one of our members) from 2005,
http://www.hallbergs.net/kx500/ Tuck\o/
