Triumph 2012 Tiger 800 Service Manual page 119

Piston Ring Gap
Note:
The piston ring gap, with the piston ring
•
fitted in the liner, must be checked before
final assembly.
1. Place the piston ring inside the liner.
2. Push the ring into the top of the cylinder, using the
g
piston to hold the rin
bore. Continue to push the ring into the bore until
the third groove of the piston is level with the
cylinder top, around the full circumference of
cylinder.
:uo
Aligning Piston Rings using the Piston
1. Remove the piston and measure the gap between
the ends of the piston ring using feeler gauges.
Piston Ring End Gap Tolerances
Top
Service limit
Second
Service limit
Oil Control
Service limit
Note:
If the end gap is too large, replace the piston
•
rings with a new set
If the gap remains too large with the new
•
piston rings, both the pistons and barrels
must be replaced
If the gap is too small, check the cylinder
•
bore for distortion, replacing as necessary.
Do not file piston rings!
Crankshaft, Connecting Rods and Pistons
square with the inside of the
0.1 5 - 0.30 mm
0.60 mm
0.30 - 0.4 5 mm
0.75 mm
0.20 - 0.70 mm
1.00 mm
Service Manual Tiger 800 and Tiger 800XC
-
Piston Assembly
1. Clean the piston ring grooves and fit the piston rings
to the piston.
Note:
The top ring upper surface is marked 'N' and
•
can be identified by a chamfer on the inside
edge.
The second ring upper surface is marked
•
'N2 ', and is plain on the inside edge
When new, the oil control rings can be fitted
•
with either face upward. Used oil control
rings must be
orientation as noted prior to removal.
Piston Ring Identification
1. Fit the piston onto the connecting rod.
Note:
Connecting rods may b e fitted either way
•
around. However, ensure all three are fitted
the same way.
2 . Lubricate the piston, small end and g udgeon pin
with a 50150 solution of engine oil and molybden um
disulphide grease.
3 . Align the small end in the connecting rod with the
gudgeon pin hole in the piston and fit the gudgeon
pin.
4.
Fit new circlips on both sides of the gudgeon pin
ensuring the circlips are correctly fitted in the
grooves.
Failure to use new g udgeon pin circlips could allow the
pin to detach from the piston. This could seize the
engine and lead to an accident.
refitted in the same
5.15