BOMBARDIER RALLY 200 2003 Shop Manual page 143

Piston Pin/Connecting Rod Bushing Clearance
Measure inside diameter of connecting rod.
CONNECTING ROD SMALL END DIAMETER
NEW MINIMUM
NEW MAXIMUM
SERVICE LIMIT
1. Connecting rod small end diameter
2. Oil supply due to oil dust
Replace crankshaft if diameter of connecting rod
small end is out of specifications. Refer to CRANK-
SHAFT for removal procedure.
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
CAUTION: Take care that piston will be installed
with the punched arrow on piston top to the
exhaust side.
VMR2003_012_03_08A.FM
15.005 mm (.5907 in)
15.015 mm (.5911 in)
15.06 mm (.593 in)
Subsection 08 (CYLINDER AND HEAD)
1. Arrow should indicate to the exhaust side
2. Area of timing chain compartment
Use the piston circlip installer (P/N 529 035 859) to
assemble the piston circlip as per following proce-
dure:
CAUTION: Secure piston pin with new piston
circlips.
– place circlip no. 40 in sleeve as per following
illustration
1. Circlip
2. Sleeve
3. Assembly jig from piston clip installer
– push taper side of assembly jig until circlip
reaches middle of sleeve
– place sleeve align with piston pin axis and push
assembly jig until circlip engages in piston.
Section 03 ENGINE
03-08-21