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Section 02 ENGINE
Sub-section 02 (253 ENGINE TYPE)
1. Head
cylmder
2 Spring
bracket
3. Lock
washer
6 mm
4.
Screw
M6
x
12
5.
InJection fliting
6.
Head
c yhnder gasket
7.
Stud
M8
x
158 5
1
41
8. Lock
washer 8.4
mm
1 41
Use engine
mounting support
(PiN 420 876 640) to hold
engine while working on
.
A003002001
CLEANING
Discard all
gaskets.
Eng1ne
mount1ng
support
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" (over an arrow on the
piston dome)
must
be visible after cleaning.
Clean the poston ring grooves with a groove
cleaner
tool,
or with a piece of broken ring.
DISASSEMBLY
10,13,14, Piston, gudgeon pin
&
circlips
Place a
clean
cloth over
crankcase
to prevent circlips from
falling into
crankcase.
With a pointed tool
inserted
in pis-
ton notch, remove circlips from piston
.
Drive the gudgeon pin out of piston using a suitable drive
punch and
hammer.
'W'
CAUTION: When tapping out gudgeon pins, hold
T
piston firmly in place to eliminate the possibilities
of transmitting shock and pressure to the connecting
rod.
02·02·4
9 Nut
M814!
10.
Clrclip
121
II. SemHrapel ring
12. Rectangular ring
13.
P1ston
14.
Gudgeon pm
15.
Needle bea,ng
INSPECTION
The inspection of the engine top end must include the
following
measurements
:
·
TOLERANCES
MEASUREMENTS
FITTING NEW PARTS
WEAR LIMIT
(MIN.)
(MAX .I
Cylinder taper
03 mm
07 mm
NA
1.0012"1
1.0028"1
Cylinder out of
N .A
NA
.10
mm
round
1.0039"1
Cylinder/piston
.08
mm
10mm
20mm
clearance
!
0031
"
}
I
0039"1
(0079
"1
Rmg/poston groove
.04
mm
11 mm
.20mm
clearance
!0016"1
(0043"1
(0079"1
Rmg end gap
20
mm
35 mm
1.0
mm
10079"
1
(0138"1
1.0394"
)
0
NOTE: For the measurement procedures, refer
to
"Engine dimensions measurement", section 02-10.
ASSEMBLY
10,13, Piston & circlips
At assembly, place the piston over the connecting rod
with the letters "AUS" (over an arrow on the piston
dome) facing in direction of the exhaust port
EXHAUST
A001002001
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