Removing The Piston; Checking The Cylinder And Piston - Yamaha XJR1300 2007 Service Manual

EAS24380

REMOVING THE PISTON

1. Remove:
Piston pin clips "1"
G
Piston pin "2"
G
Piston "3"
G
ECA13810
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
Before removing the piston pin clip, cover the
G
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
Before removing the piston pin, deburr the pis-
G
ton pin clip's groove and the piston's pin bore
area.
2. Remove:
Top ring
G
2nd ring
G
Oil ring
G
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
EAS24400

CHECKING THE CYLINDER AND PISTON

1. Check:
Piston wall
G
Cylinder wall
G
3
1
2
CYLINDER AND PISTON
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
Piston-to-cylinder clearance
G
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
a. Measure cylinder bore "C" with the cylinder
bore gauge.
NOTE:
Measure cylinder bore "C" by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Cylinder bore "C" -
Bore
79.000–79.010 mm
(3.1102–3.1106 in)
Taper limit
0.05 mm (0.0020 in)
Out of round limit
0.100 mm (0.0039 in)
Warp limit
0.03 mm (0.0012 in)
"C"=maximum of D1–D6
"T"=maximum of D1 or D2—maximum of D5
or D6
"R"=maximum of D1, D3 or D5—minimum of
D2, D4 or D6
b. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
c. Measure piston skirt diameter "D" with the mi-
crometer.
5-25