Suzuki DF 40 Service Manual page 281

Four stroke
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DF40/S0 "KS" ('05) MODEL
9
Item
Unit
i
Data
I
DF40T/40QH
t
DFSOT/SOTH/SOWT/SOWQH
CYLINDER/PISTON/PISTON RING
Cylinder distortion
I
Limit
mm (in)
i
0.060 (0.0024)
Piston to cylinder clearance
STD
mm (in)
0.020 - 0.040 (0.0008 - 0.0016)
I
Limit I
mm (in)
I
0.100 (0.0039)
Cylinder bore
I
STD
mm (in)
71.000 - 71.020 (2.7953 - 2.7961)
Cylinder measuring position
I
mm (in)
I
50 (2.0) from cylinder top surface
Piston skirt diameter
I
STD
I
mm (in)
70.970 -70.990 (2.7941 - 2.7949)
Piston measuring position
i
mm (in)
19 (0.7) from piston skirt end
Cylinder bore wear
Limit
mm (in)
0.100 (0.0039)
Piston ring end gap
STD
mm (in)
0.10-0.25 (0.004-0.010)
1st
Limit
mm (in)
D.70 (0.028)
I
STD
mm (in)
0.25 - 0.40 (0.010 - 0.016)
I
I
2nd
mm (in)
Limit
1.00 (0.039)
Piston ring free end
1st
I
STD
mm (in)
Approx. 7.5 (0.30)
gap
Limit
mm (in)
6.0 (0.24)
I
2nd
STD
mm (in)
Approx. 11.0 (0.43)
Limit
mm (in)
8.8 (0.35)
Piston ring to groove
STD
mm (in)
I
0.02 - 0.06 (0.001
0.002)
I
ClEarance
1st
I
Limit
mm (in)
0.10 (0.004)
STD
mm (in)
0.02
0.06 (0.001 - 0.002)
2nd
I
Limit
mm (in)
0.10 (0.004)
Piston ring groove
1st
STD
mm (in)
1.01
1.03 (0.040 - 0.041)
width
2nd
I
STD
mm (in)
1.01 - 1.03 (0.040 - 0.041)
Oil
STD
mm (in)
I
2.01 - 2.03 (0.079 - 0.080)
I,..
'on ring thickness
1st
I
STD
I
mm (in)
0.97
0.99 (0.038 - 0.039)
I 2nd
STD
mm (in)
0.97 - 0.99 (0.038 - 0.039)
Pin clearance In piston pin
STD
mm (in)
I
0.006 - 0.018 (0.0002 - 0.0007)
hole
I
Limit
mm (in)
0.040 (0.0016)
Piston pin outside diameter
I
STD
mm (in)
17.996-18.000 (0.7085-0.7087)
I
Limit I
mm (in)
17.980 (0.7079)
Piston pin hole diameter
I
STD
I
mm (in)
18.006 - 18.014 (0.7089 - 0.7092)
,
I
, Limit
i
mm (in)
18.040 (0.7102)
Pin clearance in conrod
'sm!
mm (in)
0.003 - 0.015 (0.0001 - 0.0006)
small end
: Limit
mm (in)
0.050 (0.0020)
Conrod small end bore
I
STD:
mm (in)
18.003-18.011 (0.7088-0.7091)

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