Yamaha XT1200Z 2010 Service Manual page 336

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
1. Install:
• Oil ring expander "1"
• Lower oil ring rail "2"
• Upper oil ring rail "3"
• 2nd ring "4"
• Top ring "5"
TIP
• Install the oil ring expander as shown in the il-
lustration.
• Be sure to install the piston rings so that the
manufacturer marks face up.
2. Install:
• Piston "1"
• Piston pin "2"
• Piston pin clips "3"
TIP
• Apply engine oil onto the piston pin.
• Make sure the punch mark "a" on the piston
points towards the exhaust side of the engine.
• Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the piston pin clips from falling into the crank-
case.
• Install the piston pin clips so that the clip ends
are 3 mm (0.12 in) "b" or more from the cutout
in the piston.
• Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#2).
1
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5
4
3
1
2
New
2
3
New
a
CYLINDER AND PISTONS
3. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:
• Piston ring end gaps
e
120˚
a. Top ring
b. Upper oil ring rail
c. Oil ring expander
d. Lower oil ring rail
e. 2nd ring
f. 40 mm (1.57 in)
A. Exhaust side
5. Install:
• Dowel pins
• Cylinder gasket
6. Install:
• Cylinder "1"
TIP
• While compressing the piston rings, install the
cylinder.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
5-41
1 2
b
3 New
120˚
a
120˚
f f
d b
c
A
New