Piston And Piston Ring Inspection - Suzuki ltz 400 Service Manual

"C"
"C": 2nd ring and lower side rail
"D": Upper side rail
"E": 1st ring and spacer
3) Install the piston and piston pin. Refer to "Engine Top
Side Assembly (Page 1D-20)".

Piston and Piston Ring Inspection

Refer to "Piston Ring Removal and Installation
(Page 1D-39)".
Piston diameter
Measure the piston diameter using the micrometer at 15
mm (0.6 in) "a" from the skirt end. If the piston diameter
is less than the service limit, replace the piston.
Special tool
(A): 09900–20204 (Micrometer (75 – 100 mm))
Piston diameter
Service limit: 89.880 mm (3.5386 in)
Piston-to-cylinder clearance
Subtract the piston diameter from the cylinder bore
diameter. If the piston-to-cylinder clearance exceeds the
service limit, replace both the cylinder and the piston.
Piston-to-cylinder clearance
Service limit: 0.120 mm (0.0047 in)
EX
"D"
IN
"E"
I933H1140146-01
B933H21406031
" a "
I933H1140147-01
(A)
I831G1140337-01
Piston ring-to-groove clearance
Measure the side clearances of the 1st and 2nd piston
rings using the thickness gauge. If any of the clearances
exceed the limit, replace both the piston and piston
rings.
Special tool
(A): 09900–20803 (Thickness gauge)
(B): 09900–20205 (Micrometer (0 – 25 mm))
Piston ring-to-groove clearance
Service limit: (1st): 0.180 mm (0.007 in)
Service limit: (2nd): 0.150 mm (0.006 in)
Piston ring groove width
"a": Standard: (1st): 0.78 – 0.80 mm (0.0307 – 0.0315
in)
"b": Standard: (1st): 1.30 – 1.32 mm (0.0512 – 0.0520
in)
Standard: (2nd): 0.81 – 0.83 mm (0.0319 – 0.0327 in)
Standard: (Oil): 2.01 – 2.03 mm (0.0791 – 0.0799 in)
Piston ring thickness
Standard: (1st):0.71 – 0.76 mm (0.0280 – 0.0299)
Standard: (1st):1.08 – 1.10 mm (0.0425 – 0.0433)
Standard: (2nd): 0.77 – 0.79 mm (0.0303 – 0.0311 in)
Engine Mechanical: 1D-40
(A)
I831G1140183-03
" b "
" a "
I933H1140242-01
(B)
I649G1140264-03