Installing The Pistons And Cylinder - Yamaha 2012 TMAX XP500A Service Manual

EAS24470

INSTALLING THE PISTONS AND CYLINDER

The following procedure applies to all of the
pistons and cylinders.
1. Install:
• Oil ring expander "1"
• Lower oil ring rail "2"
• Upper oil ring rail "3"
• 2nd ring "4"
• Top ring "5"
(into the piston)
TIP
Be sure to install the top and 2nd rings so that
the manufacturer marks or numbers "a" face
up.
2. Install:
• Piston "1"
• Piston pin "2"
• Piston pin clips "3"
TIP
• Apply engine oil onto the piston pin.
• Make sure the mark "a" on the piston points
towards the exhaust side of the cylinder.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre-
vent the piston pin clip from falling into the
crankcase.
• Install the piston pin clips so that the clip
ends are 3 mm (0.12 in) "b" or more from the
cutout in the piston.
• Reinstall each piston into its original cylinder.
New
CYLINDER AND PISTONS
3. Install:
• Dowel pins
• Cylinder gasket
4. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Offset:
• Piston ring end gaps
a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail
A. Exhaust side
5-33
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