Piston Installation - Can-Am DS 450 2008 Shop Manual

Section 03 ENGINE
Subsection 07 (CYLINDER HEAD/CYLINDER)
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same dimension as with
the micrometer, otherwise the reading will be
false.
Position the dial bore gauge 20 mm (.787 in) above
cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
PISTON/CYLINDER CLEARANCE
NEW
SERVICE LIMIT
If clearance exceeds specified tolerance, replace
piston by a new one and measure piston/cylinder
clearance again.

Piston Installation

For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: Take special care when matching the pis-
ton with cylinder:
Piston size "1" — cylinder size "A"
Piston size "2" — cylinder size "B"
The cylinder size code "A" or "B" is stamped on
the lower side of the cylinder.
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1. Size code "A" or "B" of cylinder
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
CAUTION: Take care that piston will be in-
stalled with the punched arrow on piston top
direction to exhaust valves.
110
0.040 to 0.085 mm
(.0016 to .0033 in)
0.090 mm (.0035 in)
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1. Arrow on piston must show to exhaust side of cylinder
Secure piston pin using a NEW circlip.
CAUTION: Always replace disassembled pis-
ton circlip(s) with NEW ones. Place a rag on
cylinder base to avoid dropping the circlip in-
side the engine.
To install the circlip, use the circlip installer
(P/N 529 036 083).
529036083
Place circlip in circlip installer sleeve.
Align circlip hook with circlip installer sleeve
groove.
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1. Sleeve groove
2. Circlip hook
Push circlip installer handle until circlip reaches
middle of circlip installer sleeve.
Align circlip installer sleeve with piston pin axis
and push circlip installer handle until circlip en-
gages in piston groove.
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