Cylinder/Piston Service Information; Cylinder/Piston Troubleshooting - Honda NSA700A DN-1 2009 Service Manual

SERVICE INFORMATION
GENERAL
• This section covers service o f the p iston and c y lin d er. T o service th ese parts, th e e n g in e m u s t be re m o v e d fro m th e
frame.
• Take care not to d am a g e th e cylin d e r w a lls and pistons.
• Be careful not to d a m a g e th e m ating surfaces w h e n re m o v in g the cylin d e r. Do n o t strike th e c y lird e r to o hard d urin g
removal.
• When disassembling, m ark and sto re th e d isassem b led parts to en su re th a t th e y a re rein stalled in th e ir o rig in a l lo ca­
tions.
• Clean all disassem bled parts v/ith c le a n in g s o lv e n t and d ry th e m by b lo w in g th e m o ff w ith co m p ressed a ir b efo re
inspection.
• Camshaft and rocker arm lubricating oil is fe d th ro u g h oil passages in th e cylin d e r. C lean th e oil passages b e fo re in s ta ll­
ing the cylinder.
SPECIFICATIONS
IT E M
Cylinder I.D.
O ut o f round
Taper
W arp ag e
Piston,
Piston O.D. at 15 m m (0 .59 in) fro m
piston pin,
bottom
piston rings
Piston pin bore I.D.
Piston pin O.D.
P iston-to-piston pin clearance
Piston ring end
gap
Piston ring -to-rin g
g ro ove clearance
Cylinder-to-piston clearance
i Connecting rod sm all en d I.D.
^Connecting rod-to-piston pin clearance
TROUBLESHOOTING
Compression to o lo w , hard s ta rtin g o r p o o r p e rfo rm a n c e a t lo w speed
• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or dam aged cylin d e r and piston
Compression to o high, o v e rh e a tin g o r knocking
• Excessive carbon b u ilt-u p on piston head o r c o m b u s tio n c h a m b er
Excessive smoke
• Worn cylinder, piston or piston rings
• Improper installation o f piston rings
• Scored or scratched piston o r cylin d e r w a ll
Abnormal noise
• Worn piston pin or piston pin hole
• Worn cylinder, piston o r p iston rings
• Worn connecting rod sm a ll end
8 1 .0 0 0 - 8 1 .0 1 5 (3 .1 8 90 - 3 .1896)
8 0 .9 6 0 - 8 0 .9 8 0 (3.18 78 - 3 .18 8 6 )
18.00 2 - 1 8 .0 0 8 (0 .7 0 8 7 - 0 .7 0 8 9)
17.994 - 1 8 .0 0 0 (0 .7 0 8 4 - 0 .7 0 87 )
0.0 0 2 - 0 .014 (0.0001 - 0 .0 0 0 6 )
Top 0 . 2 0 - 0 . 3 5 ( 0 . 0 0 8 - 0 . 0 1 4 )
S econd 0 . 3 5 - 0 . 5 0 ( 0 . 0 1 4 - 0 . 0 2 0 )
Oil 0 . 2 0 - 0 . 7 0 ( 0 . 0 0 8 - 0 .0 2 8 )
(side rail)
Top/ 0.015 - 0 .0 4 5 (0 .0 0 0 4 - 0.0018)
S econd
0.0 2 0 - 0 .0 5 5 (0 .0 0 0 8 - 0 .0 0 2 2 )
18.016 - 18.037 (0 .7 0 9 3 - 0.7101)
0.016 - 0 .0 4 3 (0 .0 0 0 6 - 0 .0017)
CYLINDER/PISTON
STA N D A R D
-
-
-
U nit: m m (in)
SER V IC E L IM IT
8 1 .1 0 (3 .1 9 3 )
0.0 6 (0 .0 0 2 )
0 .0 6 (0.002)
0.10 (0.0 0 4 )
8 0 .9 0 (3.185)
18.05 (0.711)
17.98 (0.708)
0 .0 4 (0.002)
0 .5 0 (0.020)
0 .6 5 (0.026)
0 .9 0 (0.035)
0 .0 7 (0.003)
0.10 (0 .004)
18.047 (0.7105)
0 .0 6 (0 .0 0 2 )