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Section 02 ENGINE
Sub-section 07 (503 ENGINE TYPE)
I. Cylmder flange
gasket
121
2
Cylmder
121
3. Cylmder head gasket
121
4.
Cylinder head 121
5.
Washer 8
.
4
mm 141
6.
Hexagonal nur 8
mm
141
7. Washer 8
.
4 mm 141
8 Distance nur 8 x 37
mm
141
9.
lnrake mamfold
gasket 141
1 0. lnrake manifold
17.
Lock washer 8 mm 141
12. Hexagonal bolt M8 x
40 mm
121
13
D-ring
CLEANING
Discard
all gaskets.
Clean
all
metal components in
a
non-ferrous metal
clean-
er.
Scrape
off carbon
formation from cylinder exhaust port,
cylinder head and piston dome using a
wooden
spatula
.
0
NOTE:
The
letters
"AUS"
lover an arrow on the pis-
ton dome) must be
visible
after
cleaning
.
Clean
th
e p1s
ton nng
grooves
with a groove
cleaner
tool,
or
with
a
piece
of
broken
ring
DISASSEMBLY
21,25,26, Piston gudgeon pin & circlips.
Place
a clean
cloth over
crankcase
to prevent
circlips
from
falling
into crankcase.
Then with a pointed tool inserted
in piston
notch,
remove
circlip
from piston
.
Drive
the
gudgeon pin out
of
piston using a
suitable
drive
punch and
hammer.
~CAUTION:
When tapping out gudgeon pins,
T
hold piston firmly
in
place to eliminate the pos
-
sibilities of transmitting shock and pressure to the con-
necting rod.
02-07-4
I 4 Intake manifold cover
15 Hexagonal
bolr
MR x
64 mm
121
16 Lock
washer
6
mm 121
I 7
Hexagonal
bolt
M6
x
30 mm 121
18.
Noise
damper
19.
Noise damper fshonl
f41
20.
Noise damper llong/141
21
Piston
121
22.
Rectangular
ring
121
23. Semi-rrapez ring 121
24. Needle beaflng 121
25
Gudgeon pin
f21
26. Circlip 141
INSPECTION
The
Inspection of the engine
top
end
must include the
following
measurements:
TOLERANCES
MEASUREMENTS
FITTING NEW PARTS
WEAR LIMIT
(MIN.)
IMAX.)
Cylinder taper
NA
NA
.08 mm
10031
"
)
Cyltnder
out of
NA
NA
.05
mm
round
10020"1
Cylinder/piston
07 mm
09
mm
.20
mm
clearance
10028"1
10035"1
10079"1
Aing/ptston
groove
04
mm
.11
mm
20
mm
clearance
10016'
1
10043"1
10079"1
Ail'lg end gap
20
mm
35
mm
1.0mm
10079"1
10138"1
10394"1
0
NOTE:
For the measurement procedures,
refer
.
to
"Engine
dimensions
measurement",
section
02-10.
ASSEMBLY
21 ,26, Pistons & circlips
At
assembly,
place the pistons over the
connecting
rods with the letters
"AUS"
(over an
arrow
on the
piston dome) facing in the direction of the exhaust port.
EXHAUST
A001002001
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