Honda XL200 2001 Shop Manual page 98

CYLINDER/PISTON
Temporarily install the piston rings in their proper positions with
the marks facing up.
Measure the piston ring-to-ring groove clearance with a feeler
gauge.
SERVICE LIMIT:
Top: 0.09 mm (0.004 in)
Second: 0.09 mm (0.004 in)
Inspect the piston for wear or damage.
Insert each piston ring into the cylinder using the piston head
and measure the ring end gap in the cylinder at a point 10 mm
(0.4 in) from the bottom.
SERVICE LIMIT:
Top: 0.5 mm (0.02 in)
Second: 0.7 mm (0.03 in)
Oil: 0.9 mm (0.04 in)
Measure the piston O.D. at 10 mm (0.4 in) from the bottom of the
skirt.
SERVICE LIMIT: 63.42 mm (2.495 in)
Compare this measurement against the service limit and use it to
calculate piston-to-cylinder clearance (see page 7-2).
Measure the piston pin bore I.D. in two direction at right angle to
each other.
SERVICE LIMIT: 15.04 mm (0.592 in)
Measure the piston pin O.D. at the left, center and right in two
direction at right angles to each other.
SERVICE LIMIT: 14.96 mm (0.589 in)
Calculate the piston-to-piston pin clearance.
SERVICE LIMIT: 0.02 mm (0.001 in)
7 -4
PISTON
CYLINDER
(10 mm (0.4 in)
XL2 0 0
PISTON RING
PISTON
PISTON PIN