Piston And Piston Ring Inspection; Piston Diameter - Suzuki RM-Z250 Owner's Service Manual

PISTON AND PISTON RING INSPECTION

PISTON DIAMETER

• Using a micrometer, measure the piston outside diameter at
8.5 mm (0.33 in) A from the piston skirt end.
• If the measurement is less than the limit, replace the piston.
" Piston diameter:
Service Limit: 76.880 mm (3.0268 in)
# 09900-20204: Micrometer (75 – 100 mm)
PISTON-TO-CYLINDER CLEARANCE
• Subtract the piston diameter from the cylinder bore diameter.
(!above)
• If the piston-to-cylinder clearance exceeds the service limit,
replace the cylinder or the piston, or both.
" Piston-to-cylinder clearance:
Service Limit: 0.120 mm (0.0047 in)
PISTON PIN AND PIN BORE
• Measure the piston pin bore inside diameter using the small
bore gauge.
• If the measurement is out of specifications replace the piston.
" Piston pin bore:
Service Limit: 16.030 mm (0.6311 in)
# 09900-20602: Dial gauge (1/1 000, 1 mm)
09900-22401: Small bore gauge (10 – 18 mm)
• Measure the piston pin outside diameter at three positions
using the micrometer.
• If any of the measurements are out of specification, replace
the piston pin.
" Piston pin O.D.:
Service Limit: 15.980 mm (0.6291 in)
# 09900-20205: Micrometer (0 – 25 mm)
at 8.5 mm (0.33 in) from the skirt end
CYLINDER HEAD, CYLINDER AND PISTON 6-21