Piston - Suzuki GSX1200 1999 Service Manual

CYLINDER BORE
Measure the cylinder bore diameter at six places. If any one of the
measurements exceeds the limit, overhaul the cylinder and re-
place the piston with an oversize piston. The remaining cylinders
must be also rebored accordingly. Otherwise, the imbalance might
cause excess vibration.
! ! ! ! ! Cylinder bore
Service Limit: 79.080 mm
" "
" " 09900-20508: Cylinder gauge set "
PISTON DIAMETER
Using a micrometer, measure the piston's outside diameter at the
place shown in Fig. If the measurement is less than the limit, re-
place the piston.
! ! ! Piston diam.
! !
Service Limit: 78.880 mm
" " 09900-20204: Micrometer (75 – 100 mm) "
" "
PISTON-CYLINDER CLEARANCE
As a result of the above measurement, if the piston clearance
exceeds the following limit, overhaul the cylinder and use an over-
size piston, or replace both cylinder and piston.
! ! ! ! Piston to cylinder clearance !
Service Limit: 0.12 mm
Piston oversize: 0.5 mm
PISTON RING-GROOVE CLEARANCE
Using a thickness gauge, measure the side clearances of the 1st
and 2nd rings. If any of the clearances exceeds the limit, replace
both piston and piston rings.
" " " 09900-20803: Thickness gauge " "
! ! Piston ring-groove clearance !
! !
Service Limit
1st : 0.18 mm
2nd: 0.15 mm
ENGINE 3-37
15 mm