Suzuki 2005 GSF1200 Service Manual page 109

Piston-to-cylinder Clearance
Subtract the piston diameter from the cylinder bore
diameter. If the piston-to-cylinder clearance exceeds the
service limit, replace both the cylinder and the piston.
Piston-to-cylinder clearance
Service limit: 0.12 mm (0.0047 in)
Piston Ring-to-groove Clearance
Measure the side clearances of the 1st and 2nd piston
rings using the thickness gauge. If any of the clearances
exceed the limit, replace both the piston and piston
rings.
Special tool
(A): 09900–20803 (Thickness gauge)
(B): 09900–20205 (Micrometer (0-25mm))
Piston ring-to-groove clearance
Service limit: (1st): 0.18 mm (0.007 in)
Service limit: (2nd): 0.15 mm (0.006 in)
Piston ring groove width
Standard: (1st): 1.01 – 1.03 mm (0.040 – 0.041 in)
Standard: (2nd): 1.01 – 1.03 mm (0.040 – 0.041 in)
Standard: (Oil): 2.01 – 2.03 mm (0.079 – 0.080 in)
Piston ring thickness
Standard: (1st): 0.975 – 0.990 mm (0.0384 – 0.0390 in)
Standard: (2nd): 0.970 – 0.990 mm (0.038 – 0.039 in)
Piston Ring Free End Gap and Piston Ring End Gap
Measure the piston ring free end gap using vernier
calipers. Next, fit the piston ring squarely into the
cylinder and measure the piston ring end gap using the
thickness gauge. If any of the measurements exceed the
service limit, replace the piston ring with a new one.
Special tool
Piston ring free end gap
Service limit: (1st): 8.0 mm (0.31 in)
Service limit: (2nd): 7.6 mm (0.30 in)
Special tool
Piston ring end gap
Service limit: (1st): 0.5 mm (0.020 in)
Service limit: (2nd): 0.7 mm (0.028 in)
(A)
I649G1140263-02
(B)
I649G1140264-02
Engine Mechanical:
(A): 09900–20102 (Vernier calipers)
(B): 09900–20803 (Thickness gauge)
1D-41
(A)
I649G1140265-02
(B)
I649G1140266-02