Piston And Piston Ring Inspection - Suzuki RMX450Z Service Manual

Piston and Piston Ring Inspection

Refer to "Piston Ring Removal and Installation"
(Page 1D-49).
Piston Diameter
Measure the piston diameter using the micrometer at 16
mm (0.63 in) "a" from the skirt end. If the piston diameter
is less than the service limit, replace the piston.
Special tool
(A): 09900–20204 (Micrometer (75 – 100 mm))
Piston diameter
Service limit: 95.880 mm (3.7748 in)
Piston-to-cylinder Clearance
Subtract the piston diameter from the cylinder bore
diameter. If the piston-to-cylinder clearance exceeds the
service limit, replace both the cylinder and the piston.
Piston-to-cylinder clearance
Service limit: 0.120 mm (0.0047 in)
Piston Ring-to-groove Clearance
Measure the side clearances of the 1st ring using the
thickness gauge. If any of the clearances exceed the
limit, replace both the piston and piston ring.
Special tool
(A): 09900–20803 (Thickness gauge)
(B): 09900–20205 (Micrometer (0 – 25 mm))
Piston ring-to-groove clearance
BA02J21406031
Service limit: (1st): 0.180 mm (0.007 in)
Piston ring groove width
"a": Standard: (1st): 0.78 – 0.80 mm (0.0307 – 0.0315
in)
"b": Standard: (1st): 1.30 – 1.32 mm (0.0512 – 0.0520
in)
Standard: (Oil): 2.01 – 2.03 mm (0.0791 – 0.0799 in)
Piston ring thickness
Standard: (1st): 0.71 – 0.76 mm (0.0280 – 0.0299)
Standard: (1st): 1.08 – 1.10 mm (0.0425 – 0.0433)
" a "
IA02J1140042-02
(A)
IA02J1140043-01
Engine Mechanical: 1D-50
(A)
IA02J1140044-01
" b "
" a "
IA02J1140045-01
(B)
I649G1140264-03