Inspection Of Piston Outer Diameter; Inspection Of Cylinder Inner Diameter - TOHATSU MFS 9.9 Owner's Manual

Remove piston pin clips 6 and piston pin, and then, piston.
7.
Write cylinder number a on the mating piston.
Do not reuse piston pin clips. Be sure to replace
with new ones.

27) Inspection of Piston Outer Diameter

1. Measure piston outer diameter between points specified.
Replace if it is less than specified value.
Piston Outer Diameter a : Standard Value
60.96 mm (2.4000 in)
Measurement point b: on the line at right
angle to piston pin.
9mm (0.28 in) above piston skirt bottom
Functional Limit :
60.90 mm (2.3976 in)

28) Inspection of Cylinder Inner Diameter

Measure cylinder inner diameters (D1 to D6) at a, b and c
1.
in crank shaft directions d (D1, D3 and D5 respectively),
and in crank web directions e (D2, D4 and D6 respectively).
Cylinder Inner Diameters (D1 to D6) : Standard Value
61.00 mm (2.4016 in)
Functional Limit :
Replace if over 61.06 mm (2.4039 in).
Note : Measure at the maximum wear points.
2. Obtain taper through calculation described below. Replace
cylinder block if it is over specified value.
Taper Limit :
D1-D5 (direction d)
D2-D6 (direction e)
Functional Limit :
0.06 mm (0.0024 in)
3. Obtain out-of-roundness through calculation described below.
Replace cylinder block if out-of-roundness is over specified value.
Out-of-roundness Limit :
D2-D1 (measuring point a)
D6-D5 (measuring point c)
Functional Limit :
0.06 mm (0.0024 in)
4st 9.9/15/20 2008
6
6
6
Do not reuse.
a
D1
D3
D5
a 15mm (0.6in)
b 35mm (1.4in)
c 55mm (2.2in)
d Crankshaft direction
e Crank web direction
6
UP
1
a
b
5
D2
a
b
D4
c
D6
d
e
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