Apply molybdenum disulfide oil solution to the cylinder
bore and piston skirt.
Install the piston with its marking hollow [A] facing exhaust
Using the piston ring compressor assembly [B] to install
the piston from the cylinder head side.
Special Tools - Piston Ring Compressor Grip: 57001-1095
Piston Ring Compressor Belt,
Crankshaft (see Crankshaft Installation)
Connecting Rod Big End Caps (see Connecting Rod In-
Cylinder (Upper Crankcase) Wear Inspection
Split the crankcase (see Crankcase Splitting).
Remove the pistons (see Piston Removal).
Assemble the cylinder (upper crankcase) [A], the cylinder
head [B] and the cylinder head gasket [C].
Tighten the cylinder head bolts (see Cylinder Head Instal-
lation in the Engine Top End chapter).
Put the crankcase upside down.
Since there is a difference in cylinder wear (upper
crankcase) in different directions, take a side-to-side and
a front-to-back measurement at each of the two locations
(total of four measurements) as shown.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, replace the crankcase.
10 mm (0.39 in.) [A]
60 mm (2.36 in.) [B]
Cylinder (Upper Crankcase) Inside Diameter
75.994 ∼ 76.006 mm (2.9919 ∼ 2.9924 in.)
Service Limit: 76.09 mm (2.996 in.)
Piston Wear Inspection
Measure the outside diameter [A] of each piston 5 mm
(0.20 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is under service limit, replace the pis-
75.959 ∼ 75.974 mm (2.9905 ∼ 2.9911 in.)
Service Limit: 75.81 mm (2.985 in.)