Piston, Connecting Rod, And Bearings Cleaning And Inspection; Piston Measurement Procedure - Suzuki XL7 2007 Service Manual

1D-172 Engine Mechanical:
Piston, Connecting Rod, and Bearings
Cleaning and Inspection
Reference: "Piston and Connecting Rod Disassemble: ".
Cleaning Procedure
NOTE
DO NOT wire brush any part of the piston.
1. Clean the piston skirts and the pins with a cleaning
solvent.
2. Clean the piston ring grooves with a groove cleaner.
Ensure that the oil ring holes and slots are clean.
WARNING
!
Refer to "Safety Glasses Caution: ".
3. Dry the piston with compressed air.
Piston Inspection Procedure
1. Inspect the pistons for the following conditions:
– Cracked ring lands, skirts or pin bosses
– Ring grooves for nicks, burrs that may cause
binding (5)
– Warped or worn ring lands (5)
– Piston pin retainer grooves for burrs (2)
– Eroded areas at the top of the piston (1)
– Scuffed or damaged skirt coating (4)
– Worn piston pin bores or worn piston pins (3)
2. Replace pistons that show any signs of damage or
excessive wear.

Piston Measurement Procedure

1. Measure piston width using the following procedure:
a. Using an outside micrometer, measure the width
of the piston at 30 mm (1.181 in) below the
crown, top (1), at the thrust surfaces of the
piston, perpendicular to the piston pin centerline.
b. Compare the measurement of the piston to its
original cylinder by subtracting the piston width
from the cylinder diameter.
c. Check your measurements with the "Engine
Mechanical Specifications".
d. If the clearance obtained through measurement
is greater than the provided specifications and
the cylinder bores are within specification,
replace the piston.
2. Measure the piston pin bore to piston pin clearances
using the following procedure:
a. Piston pin bores and pins must be free of varnish
or scuffing.
b. Use an outside micrometer to measure the
piston pin in the piston contact areas.