Checking The Piston Pin; Checking The Timing Chain Guide; Installing The Piston And Cylinder - Yamaha 2010 XMAX YP125R Service Manual

3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
TIP
The oil ring expander spacer end gap cannot be
measured. If the oil ring rail gap is excessive, re-
place all three piston rings.
Piston ring
Top ring
End gap (installed)
0.10–0.25 mm (0.0039–0.0098
in)
Limit
0.50 mm (0.0197 in)
2nd ring
End gap (installed)
0.10–0.25 mm (0.0039–0.0098
in)
Limit
0.60 mm (0.0236 in)
Oil ring
End gap (installed)
0.20–0.70 mm (0.0079–0.0276
in)
EAS37P1022

CHECKING THE PISTON PIN

1. Check:
• Piston pin
Blue discoloration/grooves → Replace the
piston pin, and then check the lubrication sys-
tem.
2. Measure:
• Piston pin outside diameter "a"
Out of specification → Replace the piston pin.
Piston pin outside diameter
13.995–14.000 mm (0.5510–
0.5512 in)
Limit
13.975 mm (0.5502 in)
CYLINDER AND PISTON (YP125R)
3. Measure:
• Piston pin bore diameter "b"
Out of specification → Replace the piston.
Piston pin bore inside diameter
14.002–14.013 mm (0.5513–
0.5517 in)
Limit
14.043 mm (0.5529 in)
4. Calculate:
• Piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston pin
and piston as a set.
• Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter "b" -
Piston pin outside diameter "a"
Piston-pin-to-piston-pin-bore
clearance
0.002–0.018 mm (0.0001–0.0007
in)
EAS37P1023

CHECKING THE TIMING CHAIN GUIDE

1. Check:
• Timing chain guide (exhaust side)
Damage/wear → Replace.
EAS37P1024

INSTALLING THE PISTON AND CYLINDER

1. Install:
• Top ring "1"
• 2nd ring "2"
• Upper oil ring rail "3"
• Oil ring expander "4"
• Lower oil ring rail "5"
TIP
Be sure to install the piston rings so that the
manufacturer marks or numbers face up.
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