Cylinder Inspection; Piston Ring Removal And Installation - Suzuki AN400 Service Manual

1D-34 Engine Mechanical:

Cylinder Inspection

Refer to "Engine Top Side Disassembly (Page1D-16)".
Refer to "Engine Top Side Assembly (Page1D-18)".
Cylinder Distortion
Check the gasket surface of the cylinder for distortion.
Use a straightedge and thickness gauge. Take clearance
readings at several places. If any reading exceeds the
service limit, replace the cylinder.
Special tool
: 09900–20803 (Thickness gauge)
Cylinder distortion
Service limit: 0.05 mm (0.002 in)
Cylinder Bore
• Inspect the cylinder wall for any scratches, nicks or
other damage.
• Measure the cylinder bore diameter at six place.
Special tool
(A): 09900–20508 (Cylinder gauge set)
Cylinder bore
Standard: 81.000 – 81.015 mm (3.1890 – 3.1896 in)
(A)
Piston-to-cylinder Clearance
B705H11406053 Refer to "Piston and Related Parts Inspection (Page1D-
35)".

Piston Ring Removal and Installation

Removal
1) Draw out the piston pin and remove the piston. Refer
to "Engine Top Side Disassembly (Page1D-16)".
2) Carefully spread the ring opening with your thumbs
and then push up the opposite side of the 1st ring (1)
to remove it.
NOTE
Do not expand the piston ring excessively
since it is apt to be broken down.
I705H1140064-01
3) Remove the 2nd ring and oil ring in the same
procedures.
Installation
NOTE
• When installing the piston ring, be careful
not to damage the piston.
• Do not expand the piston ring excessively
since it is apt to be broken down.
1) Install the piston rings in the order of the oil ring,
second ring and top ring.
a) The first member to go into the of the oil ring
groove is a spacer (1).
After placing the spacer, fit the two side rails (2).
I705H1140065-01
I705H1140025-01
B705H11406055
1
I705H1140066-02
2
1
2
I705H1140169-02