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SERVICE INFORMATION
GENERAL
•
The cylinder and piston
can
be serviced with
the
engine
installed
in the
frame.
•
Take care not to damage the cylinder wall and piston.
•
Be careful
not
to
damage
the mating surfaces when
removing
the
cylinder
.
CYLINDER/PISTON
•
Rocker arm and valve lubricating oil is fed through
th
e oil passage in the cylinder.
Clean the
oil passage before install-
ing the cylinder.
•
When
disassembl ing, mark and store the disassembled parts to ensure
that
they are
reinstalled
in their origi nal loca-
lions.
SPECIFICATIONS
Piston,
piston pin,
piston ring
ITEM
10
Out-of-round
_
:raper
Warpage
~~iston
0.0. at 20
(0.8)
from bottom
_
~iston
pin hole 1.0.
Piston
pin 0.0.
Piston-to-piston
pin clearance
Unit· mm (In)
I
102
000
STAN
CARD
SERVICE
LIMIT
.0157
-4.0163)
102.05
(4.018)
-
102015 (4
0.05 (0.002)
0.05 (0.002)
-
0.05 (O.Q02)
101.960
101.990 (
.0142 -
4.0153)
101.90
(4.012)
056
0.9058)
I
23.03
(D.907)
053
0.9055)
22.98
(O.90S)
23.002
23.008
(0.
22.994
23.000 (0.
0.002
-
0.014
(0.00
1
-
0.0006)
0.04 (0.002)
.014)
0.5
(o.oi)-
4
9
9
o
o
gap
Second
0.40
-"0".5;;5;;1:;;0".0;;
'6
"-::';0.022)
0.7
(0.03)
Piston ring end
Top
0.25
-
0.35
(0.010
~
Oil
(side
rail)
0.20
-
0.70 (0.008 - 0.028)
0.9 (O.04)
Piston
ring-to-ring
1-c';;Co~p,=-~-+
0.045 - 0.080 (0.0018 - 0.0:~0;;3~
'
!-I
_ _ _ +-:0~.0:s9;,5'J1;;0c;:.0~0~37:-!1---c
~~~~~-.L_
-,g",."o."ov~e
,
,-,clearance
Second
0.025
-
0.060
(0.0010;.:-:.:
0 :c.,,00:<2~4,,1
_ _ _
-+--;<0."i0ic75~10:ii.0~Oii3",0,-1---i
Cylinder-to-p
iston clearance
~~~':::~~~===~oJ.0~ ,go; -jO~.Og5~5tl~oB.0004
-
0.0022,""'
_ _
--1---:0~.~'9~10~.0~0~7~1,,-_1
Connecting rod small end 1.0.
23.030
-
23.050 (0.9067
-
0.9075)
23.06 (0.908)
Connecting
rod-to-piston
pin clearance
0.030 - 0.056
(0.
0012
- 0.0022)
0.08 (0.003)
TORQUE VALUES
Cylinder stud
bolt
24
N'm
(2.4
kgf.m,
18Ibf·ft)
See page 10-7
TROUBLESHOOTING
Compression too
low,
hard
starting
or poor performance at
low
speed
•
Leaking cylinder
head
gasket
•
Worn, stuck or broken piston ring
•
Worn or damaged cylinde
r
and piston
Compression too high, overheating or knocking
•
Excessive carbon built-up on piston head or combustion chamber
Excessive
smoke
•
Worn cylinder, piston or piston
rings
•
Improper
installation of piston
rings
•
Scored or scratched piston or cylinder
wall
Abnormal noise
•
Worn piston pin or piston pin bore
•
Worn connecting rod small end
•
Worn cylinder, piston or piston rings
10-3
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Table of Contents
Troubleshooting
