Cylinder/Piston Service Information; Cylinder/Piston Torque Values - Honda TRX450R Service Manual

CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
• The cylinder and piston can be serviced with the engine installed in the frame.
• Take care not to damage the cylinder wall and piston.
• Be careful not to damage the mating surfaces when removing the cylinder.
• Camshaft and rocker arm lubricating oil is fed through an oil passage in the cylinder. Clean the oil passage before
installing cylinder.
SPECIFICATIONS
'04 - ' 05:
ITEM
Cylinder
Piston,
piston pin,
piston ring
I.D.
Out-of-round
Taper
Warpage
Piston O.D. at 20 (0.8) from bottom
Piston pin hole I.D.
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end
gap
Piston ring-to-ring
groove clearance
Top
Second
Oil (side rail)
Top
Second
Cylinder-to-piston clearance
Connecting rod small end I.D.
Connecting rod-to-piston pin clearance
STANDARD
94.000 - 94.015 (3.7008 - 3.7014)
-
-
-
93.960 - 93.990 (3.6992 - 3.7004)
21.002 - 21.008 (0.8268 - 0.8271)
20.994 - 21.000 (0.8265 - 0.8268)
0.002 - 0.014 (0.0001 - 0.0006)
0.20-0.35(0.008-0.014)
0.35-0.50(0.014-0.020)
0.20-0.70(0.008-0.028)
0.065 - 0.100 (0.0026 - 0.0039)
0.030 - 0.060 (0.0012 - 0.0024)
0.010 - 0.055 (0.0004 - 0.0022)
21.016 - 21.034 (0.8274 - 0.8281)
0.016 - 0.040 (0.0006 - 0.0016)
Unit: mm (in)
SERVICE LIMIT
94.05 (3.703)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
93.86 (3.695)
21.03 (0.828)
20.98 (0.826)
0.04 (0.002)
0.50 (0.020)
0.65 (0.026)
0.9 (0.04)
0.115(0.0045)
0.075 (0.0030)
0.19(0.007)
21.04 (0.828)
0.06 (0.002)
After '05:
ITEM
Cylinder
Piston,
piston pin,
piston ring
I.D.
Out-of-round
Taper
Warpage
Piston O.D. at 10 (0.4) from bottom
Piston pin hole I.D.
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end
gap
Piston ring-to-ring
groove clearance
Top
Second
Oil (side rail)
Top
Second
Cylinder-to-piston clearance
Connecting rod small end I.D.
Connecting rod-to-piston pin clearance
STANDARD
96.000 - 96.015 (3.7795 - 3.7801)
-
-
-
95.970 - 95.980 (3.7783 - 3.7787)
19.002 - 19.008 (0.7481 - 0.7483)
18.994 - 19.000 (0.7478 - 0.7480)
0.002 - 0.014 (0.0001 - 0.0006)
0.25-0.31 (0.010-0.012)
0.23-0.33(0.009-0.013)
0.20-0.70(0.008-0.028)
0.065 - 0.100 (0.0026 - 0.0039)
0.065 - 0.100 (0.0026 - 0.0039)
0.020 - 0.045 (0.0008 - 0.0018)
19.016 - 19.034 (0.7487 - 0.7494)
0.016 - 0.040 (0.0006 - 0.0016)
Unit: mm (in)
SERVICE LIMIT
96.05(3.781)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
95.87 (3.774)
19.03 (0.749)
18.98(0.747)
0.04 (0.002)
0.45 (0.018)
0.48 (0.019)
0.90 (0.035)
0.115(0.0045)
0.115(0.0045)
0.18(0.007)
19.04 (0.750)
0.06 (0.002)
TORQUE VALUES
Cylinder stud bolt
Cam chain tensioner lifter bolt (After '05)
See page 12-9
12N-m(1.2kgfm, 9 Ibfft) Apply locking agent to the threads.
12-3