Connecting Rods And Pistons; Removing The Connecting Rods And Pistons; Checking The Cylinder And Piston - Yamaha Tenere 700 2020 Service Manual

EAS30745
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the con-
necting rods and pistons.
1. Remove:
• Connecting rod cap
• Connecting rod
• Big end bearings
TIP
• Identify the position of each connecting rod cap
so that it can be reinstalled in its original place.
• After removing the connecting rods and con-
necting rod caps, care should be taken not to
damage the mating surfaces of the connecting
rods and connecting rod caps.
2. Remove:
• Piston pin clips "1"
• Piston pin "2"
• Piston
• Connecting rod
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• For reference during installation, put identifica-
tion marks on the piston crown.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar-
ea. If both areas are debarred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set "3".
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
2
G088998
3. Remove:
• Top ring
• 2nd ring
1
3

CONNECTING RODS AND PISTONS

• Oil ring
TIP
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
G088999
EAS30747

CHECKING THE CYLINDER AND PISTON

The following procedure applies to all of the cyl-
inders and pistons.
1. Check:
• Piston wall
• Cylinder wall
Vertical scratches → Replace the cylinder,
and replace the piston and piston rings as a
set.
2. Measure:
• Piston-to-cylinder clearance
a. Measure cylinder bore with the cylinder
bore gauge.
TIP
Measure cylinder bore by taking side-to-side
and front-to-back measurements of the cylinder.
Bore
Wear limit
"C" = maximum of D
G089000
5-67
80.000–80.010 mm (3.1496–
3.1500 in)
80.060 mm (3.1520 in)
, D , D , D , D
1 2 3 4
, D
5 6