Suzuki SQ416 Service Manual page 57

6A2-12 ENGINE MECHANICAL (H25 ENGINE)
Cylinder Block
Distortion of gasketed surface
D Using straightedge and thickness gauge, check gasketed sur-
face for distortion and, if flatness exceeds its limit, correct it.
Flatness Limit: 0.06 mm (0.0024 in.)
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must also
be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
Size Piston diameter
STD 83.970 – 83.990 mm (3.3059 – 3.3067 in.)
O/S 0.50 84.470 – 84.490 mm (3.3256 – 3.3264 in.)
3) Using micrometer, measure piston diameter.
4) Calculate cylinder bore diameter to be rebored as follows.
D = A + B – C
D: Cylinder bore diameter to be rebored
A: Piston diameter as measured
B: Piston clearance = 0.02 – 0.04 mm
(0.0008 – 0.0015 in.)
C: Allowance for honing = 0.02 mm
(0.0008 in.)
5) Rebore and hone cylinder to calculated dimension.
NOTE:
Before reboring, install all main bearing caps in place and
tighten to specification to avoid distortion of bearing bores.
6) Measure piston clearance after honing.