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If clearance exceeds specified tolerance, replace
piston by a new one and measure piston/cylinder
clearance again.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Connecting Rod/Piston Pin Clearance
Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
damages.
Measure piston pin. See the following illustration
for the proper measurement positions.
R400motr30A
A. Piston pin diameter
PISTON PIN DIAMETER
NEW
570
AND 850
SERVICE
ENGINES
LIMIT
NEW
1000R
ENGINE
SERVICE
LIMIT
Replace piston pin if diameter is out of specifica-
tions.
Measure inside diameter of connecting rod small
end bushing.
vmr2016-419
A
19.996 mm to 20.000 mm
(.7872 in to .7874 in)
19.980 mm (.7866 in)
21.996 mm to 22.000 mm
(.866 in to .866 in)
21.980 mm (.8654 in)
Subsection 08 (TOP END)
2
R1004motr11A
1. Bore gauge
2. Connecting rod
CONNECTING ROD SMALL END DIAMETER
NEW
570
AND 850
SERVICE
ENGINES
LIMIT
NEW
1000R
ENGINE
SERVICE
LIMIT
Replace connecting rod if diameter of connecting
rod small end is out of specifications. Refer to
BOTTOM END
subsection for removal proce-
dure.
Compare measurements to obtain the connecting
rod/piston pin clearance.
CONNECTING ROD/
PISTON PIN CLEARANCE
SERVICE LIMIT
Installing the Piston
Reverse the removal procedure. Pay attention to
the following details.
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
570, 850 and 1000R Engines
For each cylinder, install piston with the punched
arrow on piston dome pointing towards the rear
side of the engine.
Front cylinder: Mark on top of piston must show
to intake side.
Rear cylinder: Mark on top of piston must show
to exhaust side.
1
20.010 mm to 20.020 mm
(.7878 in to .7882 in)
20.060 mm (.7898 in)
22.010 mm to 22.020 mm
(.8665 in to .8669 in)
22.050 mm (.8681 in)
0.080 mm (.0031 in)
23
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Troubleshooting
