Periodic Maintenance Procedures
Piston/Cylinder Clearance Inspection
The piston-to-cylinder clearance is measured whenever a
piston or cylinder is replaced with a new one. The standard
piston-to-cylinder clearance must be adhered to whenever
the cylinder is replaced.
If only a piston is replaced, the clearance may exceed the
standard slightly. But it must not be less than the minimum,
in order to avoid piston seizure.
The most accurate way to find the piston clearance is
by making separate piston and cylinder diameter measure-
ments and then computing the difference between the two
values. Measure the piston diameter as just described, and
measure the cylinder diameter at the very bottom of the
0.020 ∼ 0.042 mm (0.00079 ∼ 0.0016 in.)
Piston, Piston Ring and Piston Pin Replacement
Refer to the Cylinder and Piston Section in Engine Top
Exhaust System Inspection
The exhaust system, in particular the muffler body, is de-
signed to reduce exhaust noise and conduct the exhaust
gases away from the rider while minimizing power loss. If
carbon has built up inside the muffler body, exhaust effi-
ciency is reduced, causing engine performance to drop.
If the muffler body is badly damaged, dented, cracked or
rusted, replace it. Replace the muffler baffle if the exhaust
noise becomes too loud or engine performance drops.
Muffler Baffle Change
Right Side Cover (see Side Cover Removal in the Frame
Muffler Pipe Mounting Bolts [A]
Muffler Mounting Bolt (Rear) [B]
Tap the bracket [A] of the muffler body with a plastic mallet
[B] to separate from the inner pipe.
PERIODIC MAINTENANCE 2-23