Apply molybdenum disulfide oil solution to the cylinder
bore, piston skirt and piston rings.
Install the piston with its marking hollow [A] facing exhaust
Using the piston ring compressor assembly [B] to install
the piston from the cylinder head side.
Special Tools - Piston Ring Compressor Grip: 57001-1095
Piston Ring Compressor Belt,
Crankshaft (see Crankshaft Installation)
Connecting Rod Big End Cap (see Connecting Rod In-
Cylinder Wear (Upper Crankcase)
Since there is a difference in cylinder wear (upper
crankcase) in different directions, take a side-to-side and
a front-to-back measurement at each of the two locations
(total of four measurements) shown in the figure.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, replace the crankcase.
10 mm (0.39 in.) [A]
60 mm (2.36 in.) [B]
Cylinder Inside Diameter
67.000 ∼ 67.012 mm (2.6378 ∼ 2.6383 in.)
Service Limit: 68.09 mm (2.64 in.)
Measure the outside diameter [A] of each piston 5 mm
(0.20 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is under service limit, replace the pis-
66.975 ∼ 66.990 mm (2.6368 ∼ 2.6374 in.)
Service Limit: 66.83 mm (2.631 in.)
Piston Ring, Piston Ring Groove Wear
Check for uneven groove wear by inspecting the ring seat-
The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
With the piston rings in their grooves, make several mea-
surements with a thickness gauge [A] to determine piston
Piston Ring/Groove Clearance
0.05 ∼ 0.09 mm (0.0020 ∼ 0.0035 in.)
0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
0.19 mm (0.0075 in.)
0.17 mm (0.0067 in.)