Piston And Piston Pin - Suzuki DR 125 Service Manual

CYLINDER BORE
Measure the cylinder bore diameter at six places.
If any one of the measurements exceed the limit, overhaul the
cylinder and replace the piston with an oversize piston, or
replace the cylinder.
$ Cylinder bore
Service Limit: 57.110 mm (2.2484 in)
& 09900-20508: Cylinder gauge set

PISTON AND PISTON PIN

DIAMETER
Measure the piston diameter using the micrometer at 12 mm
from the skirt end.
If the piston diameter is less than the service limit, replace the
piston.
$ Piston diameter
Service Limit: 56.880 mm (2.2394 in)
Piston oversize: 0.5 mm (0.02 in)
& 09900-20203: Micrometer (50 – 75 mm)
PISTON-TO-CYLINDER CLEARANCE
Subtract the piston diameter from the cylinder bore diameter. If
the piston-to-cylinder clearance exceeds the service limit, rebore
the cylinder and use an oversize piston or replace both the cylin-
der and the piston.
$ Piston-to-cylinder clearance
Service Limit: 0.120 mm (0.0047 in)
PISTON RING GROOVE CLEARANCE
Measure the side clearance of the 1st and 2nd rings using the
thickness gauge If any of the clearances exceed the limit,
replace both the piston and piston rings.
$ Piston ring to groove clearance
Service Limit 1st : 0.18 mm (0.007 in)
2nd : 0.15 mm (0.006 in)
& 09900-20803: Thickness gauge
09900-20205: Micrometer (0 – 25 mm)
ENGINE 3-31
12 mm (0.5 in)