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Section 02
ENGINE
Sub-section 09
(537 ENGINE TYPE)
I Cap nuT
MB
11
21
2 Cylm
der
head
3.
S rud
M6
x
15
1
2
1
4
.
Coolant
ouTlet collar
5
Loctire 242 blue (medium
strength
!
6
Lock
washer
6
mm
141
?.
NuT
M6
141
8
Gas<eT
rO-r:ng
'
r2i
9.
Gasket
121
10.
Cap nur M8 18!
1
I
FlaT
washer
8.4
181
12.
Cvimder
12!
CLEANING
Discard
all
gaskets
and
o-rings
.
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 «AUSn (over an
arrow on
the
piston dome) must
be
visible
after
cleaning
.
Clean
th
e
piston
nng
grooves
wtth
a
groove
cleaner
tool,
or wrth a piece
of
broken
ring
.
DISASSEMBLY
16, 17, 18, Piston, gudgeon pin & circlips
Place
a
clean cloth over crankcase
then
with
a pointed
tool
inserted
in ptston
notch,
remove circlip
from
piston
Drive
the
gudgeon
pin
out of
piston
using
a suita
ble
drive
punch
and hammer
.
..r
CAUTION: When tapping gudgeon pin or out of
T
piston,
hold piston firmly in place to eliminate the
possibilities of transmitting shock and pressure to the
connecting
rod.
INSPECTION
The
inspection of
the
engine
top end must include
the
fol-
lowing
measurements
:
02-09-4
13
. Cvi•nder!
crankcase ga
ske:
121
14
.
L-ring
15
Rec
tangu
lar-ring
16
P•ston
I
7.
Gudgeon
pm
18
.
ClfCIIp
/41
19
Needle
bearing
20
Cylmder
slud
MB
•
79
181
21
Slud lheadl M8 x
50
/121
22
.
GaskeT
23.
Water
outlet
socket
TOLERANCES
MEASUREMENTS
FITTING NEW PARTS
(MIN.}
(MAX.)
Cylinder
NA
N
A
taper
(ylrnder
out
of
NA
NA
round
Cvllndel
/pJston
0
9
·nrn
11
mm
clearance
(
0035"
1
10043"1
R,nglpision
groove
04
mm
.'10
rnm
clearance
I
0016"1
1.0039"1
Rrog
end gap
20
rn
rn
35
rnm
(
0019"1
!0138"
1
WEAR
LIMIT
.08
mm
(0031
"
1
05
mm
(0020"
I
.20
mm
!0079"1
20
mm
coo
nn
1
0
mm
I
0394"
1
0
NOTE
:
For the
measurement procedures,
refer
to·
"Engine
dimensions
measurement", section 02-10
.
ASSEMBLY
16, Piston
At
assembly,
place the pistons
over the connect1ng rods
with
the
letters
AUS
(over
an arrow on
the
piston
dome)
facing in direction of the
exhaust
port.
EXHAUST
A00
100200
1
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