Piston Ring Measurement Procedure - Suzuki XL7 2007 Service Manual

3. Using an inside micrometer, measure the piston pin
bore. Compare your result with the piston pin
diameter and piston pin to piston pin bore clearance
listed in the "Engine Mechanical Specifications".
4. If the clearance is excessive, determine which piece
is out of specification and replace as necessary.
5. You must replace the piston if any of its dimensions
are out of specification.
6. If the new piston does not meet clearance
specifications, the cylinder block may need to be
oversized to 0.25 mm (0.010 in). There is only one
size of oversized pistons and rings available for
service.

Piston Ring Measurement Procedure

1. Measure the piston ring end gap using the following
procedure:
a. Place the piston ring in the area of the bore
where the piston ring will travel approximately 25
mm (1 in) down from the deck surface. Ensure
that the ring is square with the cylinder bore by
positioning the ring with the piston head.
b. Measure the end gap of the piston ring with
feeler gages. Refer to "Engine Mechanical
Specifications".
c. If the clearance exceeds the provided
specifications, the piston rings must be replaced.
d. Repeat the procedure for all the piston rings.
2. Measure the piston ring side clearance using the
following procedure:
a. Roll the piston ring entirely around the piston ring
groove. If any binding is caused by the ring
groove, dress the groove with a fine file. If any
binding is caused by a distorted piston ring,
replace the ring.
b. With the piston ring on the piston, use feeler
gages to check clearance at multiple locations.
c. Compare the measurements with piston ring side
clearance listed in the "Engine Mechanical
Specifications".
d. If the clearance is greater than specifications,
replace the piston rings.
Engine Mechanical: 1D-173