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11.
CYLINDER/PISTON
SERVICE INFORMATION
TROUBLESHOOTING
CYLINDER REMOVAL
PISTON REMOVAL
SERVICE INFORMATION
GENERAL
11-1
11-2
11-3
11-5
CRANKCASE STUD BOLT
INSPECTION
PISTON INSTALLATION
CYLINDER INSTALLATION
11-8
11-8
11-10
• The engine must be removed from the frame before servicing the cylinder and piston.
• Take care not to damage the cylinder wall and piston.
• Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder.
• Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
SPECIFICATIONS
Unit: mm (in)
ITEM
STANDARD
SERVICE LIMIT
Cylinder
1.0.
19.000 -19.015 (3.1102 - 3.1108)
19.10 (3.114)
Out of round
- -
0.06 (0.002)
Taper
- -
0.06 (0.002)
Warpage
- -
0.10 (0.004)
Piston, piston
Piston mark direction
"IN" mark facing toward the intake side
- -
rings
Piston 0.0.
18.91 - 18.99 (3.109 - 3.110)
18.90 (3.106)
Piston 0.0. measurement point
1- 11 mm (0.3 - 0.1 in) from bottom of skit
- -
Piston pin bore 1.0.
18.002 - 18.008 (0.1081- 0.1090)
18.05 (0.111)
Piston pin 0.0.
11.994 - 18.000 (0.1084 - 0.7081)
11.98 (0.108)
Piston-to-piston pin clearance
0.002 - 0.014 (0.0001 - 0.0006)
0.04 (0.002)
Piston ring-to-ring
Top
0.025 - 0.055 (0.0010 - 0.0022)
0.08 (0.003)
groove clearance
Second
0.015 - 0.045 (0.0006 - 0.0018)
0.01 (0.003)
Piston ring end gap
Top
0.20 - 0.35 (0.008 - 0.014)
0.5 (0.02)
Second
0.35 - 0.50 (0.014 - 0.020)
0.1 (0.03)
Oil (side rail)
0.20 - 0.80 (0.008 - 0.031)
1.0 (0.04)
Piston ring mark
Top
"R" mark
- -
Second
"RN" mark
- -
Cylinder-to-piston clearance
0.010:-- 0.045 (0.0004 - 0.0018)
0.10 (0.004)
Connecting rod small end I.D.
18.016 - 18.034 (0.1093 - 0.1100)
18.11(0.111)
Connecting rod-to-piston pin clearance
0.016 - 0.040 (0.0006 - 0.0016)
0.06 (0.002)
m
11-1

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