Service Manual

5-16 ENGINE TOP END
Cylinder, Piston
Piston Ring End Gap
•
Remove the piston rings.
•
Push each ring (one at a time) in the cylinder bore to a point close
to the bottom of the cylinder bore.

Use the piston to push it in to be sure it is square.
•
Measure the gap [A] between the ends of the ring [B] with a thickness
gauge.
If the end gap of any ring is greater than the service limit, replace the
entire set of rings.
Piston Ring End Gap
Service Limit
Top 0.75 mm (0.029 in.)
Second 0.75 mm (0.029 in.)
Oil 1.05 mm (0.041 in.)
Piston Pin, Piston Pin Hole, and Connecting Rod Wear
•
Remove the piston pin.
•
Measure the diameter of the piston pin with a micrometer at several
points.
If the outside diameter is less than service limit, replace the piston
pin.
Piston Pin Outside Diameter
Service Limit: 15.96 mm (0.628 in.)
•
Measure the inside diameter [A] of the piston pin hole at several points
on both side. Use a dial bore gauge.
If the inside diameter is more than the service limit, replace the piston.
Piston Pin Hole Inside Diameter
Service Limit: 16.08 mm (0.633 in.)
•
Measure the inside diameter [A] of the small end of the connecting
rod at several points. Use a dial bore gauge.
If the inside diameter is more than the service limit, replace the
connecting rod.
Connecting Rod Small End Inside Diameter
Service Limit: 16.05 mm (0.632 in.)