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30/ENGINE - WORK ON INDIVIDUAL PARTS
Checking/measuring the piston
19.25
Checking the piston ring end gap
19.26
–
Check the piston bearing surface for damage.
»
If the piston sliding surface is damaged:
–
Change the piston and, if necessary, the cylinder.
–
Check that the piston rings can move easily in the piston ring grooves.
»
If the piston ring is stiff:
–
Clean the piston ring groove.
600253-01
–
Check the piston rings for damage.
»
If the piston ring is damaged:
–
Change the piston ring.
–
Check the piston pin for discoloration or signs of wear.
»
If the piston pin has strong discoloration or signs of wear:
–
Change the piston pin.
–
Insert the piston pin into the connecting rod and check the bearing for play.
»
If the piston pin bearing has too much play:
–
Change the connecting rod and the piston pin.
–
Measure the piston at the piston skirt, at right-angles to the piston pin.
Specification
Piston diameter (450 XC ATV)
Size I
Size II
Piston diameter (525 XC ATV)
200161-10
Size I
Size II
Info
Piston size
–
Remove the piston ring from the piston.
–
Place the piston ring in the cylinder and align it with the piston.
Specification
under the upper edge of the cylinder
–
Measure the end gap with feeler gauge
Specification
Piston ring - end gap
Compression ring
200163-10
Oil scraper ring
»
If the end gap is greater than the specified value:
–
Check/measure the cylinder. (
»
If the cylinder wear is within the tolerance range:
–
Change the piston ring.
–
Mount the piston ring with the marking facing toward the piston head.
Tip
Use an old piston ring to clean the piston ring groove.
Info
Mount the piston ring with the marking facing upward.
88.916... 88.946 mm (3.50062...
3.5018 in)
88.926... 88.958 mm (3.50102...
3.50228 in)
94.932... 94.960 mm (3.73747...
3.73858 in)
94.940... 94.968 mm (3.73779...
3.73889 in)
is marked on the piston head.
10 mm (0.39 in)
.
< 0.80 mm (< 0.0315 in)
< 1.00 mm (< 0.0394 in)
P. 113)
114
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