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Piston ring side clearance Top ring
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0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in) <Limit>: 0.10 mm (0.0039 in)
Nd ring
0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in) <Limit>: 0.10 mm (0.0039 in)
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CYLINDER AND PISTON ENG
9) Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the piston crown as shown.
a 10 mm (0.39 in)
• Measure:
piston ring end gap
Out of specification → Replace the piston ring.
NOTE:
The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.
Piston ring end gap Top ring
0.15 ~ 0.25 mm
(0.0059 ~ 0.0098 in) <Limit>: 0.50 mm (0.0197 in)
Nd ring
0.40 ~ 0.50 mm
(0.0157 ~ 0.0197 in) <Limit>: 0.75 mm (0.0295 in)
Oil ring
0.10 ~ 0.35 mm
(0.0039 ~ 0.0138 in)
EAS00266
CHECKING THE PISTON PINS
The following procedure applies to all of the piston pins.
• Check:
piston pin
Blue discoloration/grooves → Replace the piston pin and then check the lubrication system.
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CYLINDER AND PISTON ENG
12. Measure:
piston pin outside diameter a
Out of specification → Replace the piston pin.
Piston pin outside diameter 14.991 ~ 15.000 mm (0.5902 ~ 0.5906 in)
<Limit>: 14.971 mm (0.5894 in)
12. Measure:
piston pin bore diameter b (in the piston) Out of specification → Replace the piston pin.
Piston pin bore diameter 15.002 ~ 15.013 mm (0.5906 ~ 0.5911 in)
<Limit>: 15.043 mm (0.5922 in)
13. Calculate:
piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston pin.
Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter (in the piston) – Piston pin outside diameter
Piston-pin-to-piston-pin-bore clearance
0.002 ~ 0.022 mm
(0.00008 ~ 0.00087 in) <Limit>: 0.072 mm (0.0028 in)
EAS00271
INSTALLING THE PISTONS AND
CYLINDERS
The following procedure applies to all of the pistons and cylinders.
15. Install:
top ring
2nd ring
oil ring
NOTE:
Be sure to install the top and 2nd rings so that the manufacturer’s marks or numbers face up.
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CYLINDER AND PISTON ENG
12. Install:
piston
piston pin
piston pin clip New
NOTE:
13. Apply engine oil onto the piston pin.
14. Make sure that the punch mark a on the pis-ton points towards the exhaust side of the cylinder.
15. Before installing the piston pin clip, cover the crankcase opening with a clean rag to pre-vent the clip from falling into the crankcase.
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3. Install:
• gasket 1 New
• dowel pins
10. Lubricate:
• piston
• piston rings
• cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
13. Offset:
• top ring
• 2nd ring
• oil ring
Offset the piston ring end gaps as shown.
a Top ring end
b Upper oil ring rail end c Oil ring expander end d Lower oil ring rail end e 2nd ring end
f 20 mm (0.79 in)
13. Install:
• cylinder
• timing chain guide (exhaust side)
NOTE:
Pass the timing chain through the timing chain cavity.
5 - 36
STARTER CLUTCH AND A.C. MAGNETO ROTOR ENG
STARTER CLUTCH AND A.C. MAGNETO ROTOR
| Order | Job/Part | Q’ty | Remarks |
| Removing the starter clutch and | Remove the parts in the order listed. | ||
| A.C. magneto rotor | |||
| Left side panel/lower side cover mould- | Refer to “COVER AND PANEL” in chap- | ||
| ing/footrest board | ter 3. | ||
| Coolant | Drain. | ||
| Refer to “CHANGING THE COOLANT” in | |||
| chapter 3. | |||
| Engine oil | Drain. | ||
| Refer to “CHANGING THE ENGINE OIL” | |||
| in chapter 3. | |||
| Water pump assembly | Refer to “WATER PUMP” in chapter 6. | ||
| Starter coil assembly coupler | Disconnect. | ||
| A.C. magneto cover | Refer to “INSTALLING THE A.C. MAG- | ||
| NETO ROTOR”. | |||
| A.C. magneto cover gasket | |||
| Dowel pin | |||
5 - 37
STARTER CLUTCH AND A.C. MAGNETO ROTOR ENG
| Order | Job/Part | Q’ty | Remarks | ||
| Oil tank | |||||
| Gasket | |||||
| Dowel pin | |||||
| Oil strainer | |||||
| Starter coil assembly | |||||
| A.C. magneto rotor nut | Refer to “REMOVING THE A.C. MAG- | ||||
| Spacer | NETO ROTOR” and “INSTALLING THE | ||||
| A.C. magneto rotor | A.C. MAGNETO ROTOR”. | ||||
| Starter clutch | |||||
| Woodruff key | |||||
| Starter clutch idler gear shaft | |||||
| Starter clutch idler gear | |||||
| Starter clutch gear | |||||
| Washer | |||||
| For installation, reverse the removal pro- | |||||
| cedure. | |||||
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STARTER CLUTCH AND A.C. MAGNETO ROTOR ENG
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