Service Manual

ENGINE TOP END 5-17
Cylinder, Piston
Piston Diameter
•
Measure the outside diameter [A] of the piston 12.5 mm (0.9 in.) up
[B] from the bottom of the piston at a right angle to the direction of
the piston pin hole.
If the measurement is less than the service limit, replace the piston.
Piston Diameter
Service Limit: 64.79 mm (2.551 in.)
Cylinder Inside Diameter
•
Clean and measure the cylinder inside diameter.

Use a dial bore gauge to measure front-to-back and side-to-side at
the points shown figure.
If any of the cylinder bore measurements is greater than the service
limit, the cylinder must be bored to the next oversize and then honed
(see Cylinder Boring and Honing).
Cylinder Inside Diameter
Item standard Service Limit
Standard Cylinder 64.98 65.00 mm 65.10 mm
(2.558 2.559 in.) (2.563 in.)
0.5 mm Oversize 65.48 65.50 mm 65.60 mm
Cylinder (2.578 2.579 in.) (2.583 in.)
Cylinder Bore Out-of-Round
Standard: 0.01 mm (0.004 in.)
Service Limit: 0.056 mm (0.0022 in.)
Cylinder Boring and Honing
Always resize to exactly 0.5 mm (0.02 in.) over the standard bore
size.
If this is done accurately, the stock oversize rings and piston will fit
perfectly and proper clearance will be maintained.
Resizing the cylinder bore can be done by reliable repair shop or by
using a drill press and honing tool.
Use the stone recommended by the hone manufacturer to produce
correct cylinder wall finish.
Machine-bore first, the bore diameters should be shown in the table.
Final Boring Bore Diameter
Oversize Final Boring Bore Diameter
65.46
65.48 mm0.50 mm
(2.577 2.578 in.)
Final Bore Diameter
Oversize Final Bore Diameter
65.48
65.50 mm
0.50 mm
(2.578 2.579 in.)