Service Manual

ENGINE TOP END 5-13
Cylinder, Piston
Piston Installation
•
Install the expander [A] in the piston oil ring groove so that the
expander ends [B] touch together, never overlap.
•
Install the upper and lower steel rails. There is no UP or Down to the
rails. They can be installed either way.
•
Do not mix up the top and second rings.
•
Install the second ring so that the “0” mark faces up.
•
Install the top ring.
•
The rings should turn freely in the grooves.
[A] Piston Head
[B] Top Ring
[C] Second Ring
•
Align the piston and rings with the piston ring end gap as shown.
[A]. Arrow Match Marks
[B]. Top ring End Gap, Upper Steel Rail End Gap
[C]. 30

45

[D]. Second Ring End Gap, Lower Steel Rail End Gap
•
Apply engine oil to the piston pins.
Assemble the pistons onto the connecting rods as follow:
No.1 cyl. Piston, align the arrow mark on the piston head with the
raised letters (K Mark) on the connecting rod.
No.2 cyl. piston, align the arrow mark on the piston head opposite K
Mark on the connecting rod.
[A]. No.1 Cyl. Piston
[B]. No.2 Cyl. Piston
[C]. Arrow Marks
[D]. K Mark
[E]. Opposite K Mark
•
When installing a piston pin snap ring, compress it only enough to
install it and no more.
Fit a new piston pin snap ring into the side of the piston so that the
ring opening [A] does not coincide with the notch [B] in the edge of the
piston pin hole.
CAUTION
Do not reuse the snap rings, as removal weakens and deforms
them. They could fall out and score the cylinder wall.