BOMBARDIER RALLY 200 2003 Shop Manual page 142

Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
1. Micrometer set to the piston dimension
With the micrometer set to the dimension, adjust a
cylinder bore gauge to the micrometer dimension
and set the indicator to 0 (zero).
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
TYPICAL
1. Indicator set to 0 (zero)
03-08-20
Position the dial bore gauge 47 mm (1.85 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 NOMINAL
SERVICE LIMIT
NOTE: Make sure used piston is not worn. See
Piston Measurement above.
If clearance exceeds specified tolerance, replace
cylinder.
NOTE: Make sure the cylinder bore gauge indicator
is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Piston Pin
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.
A. Piston pin diameter
PISTON PIN
NEW MINIMUM
NEW MAXIMUM
SERVICE LIMIT
Replace piston pin if diameter is out of specifications.
0.042 to 0.072 mm
(.0017 to .0028 in)
0.090 mm (.004 in)
14.997 mm (.5904 in)
15.000 mm (.5905 in)
14.990 mm (.5902 in)
VMR2003_012_03_08A.FM