Service Manual

ENGINE TOP END 5-21
Cylinder, Piston
Piston Ring End Gap
•
Remove the piston rings (see Piston Removal).
•
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 with new ones.
Piston Ring End Gap
Service Limit:
Top 0.6 mm (0.024 in.)
Second 0.9 mm (0.035 in.)
Oil 1.1 mm (0.043 in.)
Piston Pin, Piston Pin Hole, and Connecting Rod
Wear
•
Remove the piston pin (see Piston Removal).
•
Measure the outside diameter of the piston pin with a mi-
crometer at several points.
If the outside diameter is less than service limit, replace
the piston pin with a new one.
Piston Pin Outside Diameter
Service Limit: 16.96 mm (0.668 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 greater than the service limit, re-
place the piston with a new one.
Piston Pin Hole Inside Diameter
Service Limit: 17.08 mm (0.672 in.)
•
Measure the inside diameter [A] of the connecting rod
small end at several points. Use a dial bore gauge.
If the inside diameter is more than the service limit, re-
place the connecting rod with a new one.
Connecting Rod Small End Inside Diameter
Service Limit: 17.06 mm (0.672 in.)