The kohler measuring point on the piston- is it the biggest point? could be that kohler is having you measure where it is a long flat section and giving a big # which equates to a decent clearance.
I would guess the aftermarket piston alloy is different- stay to the top half of the scale. I try for center.
Mahle piston is hyperutectic and has a lower expansion without a metal ring cast in it. *my guess*.
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