Honda TRX450R Service Manual page 234

CYLINDER/PISTON
Insert the piston ring into the bottom of the cylinder
squarely using the piston crown.
Measure the ring end gap.
SERVICE LIMITS:
'04 - '05;
Top: 0.50 mm (0.020 in)
Second: 0.65 mm (0.026 in)
Oil (side rail): 0.9 mm (0.04 in)
After '05;
Top: 0.45 mm (0.018 in)
Second: 0.48 mm (0.019 in)
Oil (side rail): 0.90 mm (0.035 in)
'04- '05: Measure the piston O.D. at a point 20 mm (0.8 in)
from the bottom and 90° to the piston pin hole.
SERVICE LIMIT: 93.86 mm (3.695 in)
After '05: Measure the piston O.D. at a point 10 mm (0.4 in)
from the bottom and 90° to the piston pin hole.
SERVICE LIMIT: 95.87 mm (3.774 in)
Compare this measurement against the maximum
cylinder I.D. measurement and calculate the cylin-
der-to-piston clearance (page 12-7).
Measure the piston pin hole I.D. Take the maximum
reading to determine the I.D.
SERVICE LIMITS:
'04 - '05; 21.03 mm (0.828 in)
After '05; 19.03 mm (0.749 in)
Measure the piston pin O.D. at three points.
SERVICE LIMITS:
'04 - '05; 20.98 mm (0.826 in)
After '05; 18.98 mm (0.747 in)
Calculate the piston-to-piston pin clearance.
SERVICE LIMIT: 0.04 mm (0.002 in)
CONNECTING ROD
Measure the connecting rod small end I.D.
SERVICE LIMITS:
'04-'05; 21.04 mm (0.828 in)
After '05; 19.04 mm (0.750 in)
Calculate the connecting rod-to-piston pin clear-
ance.
SERVICE LIMIT: 0.06 mm (0.002 in)
PISTON RING
'04-'05: 20 mm (0.8 in)
After'05:10mm (0.4 in)
12-8