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Piston Protrusion from Crankcase
Top
caution |
Do not fail to check
piston protrusions. The engine performance
are
directly influenced by them.
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Standard
value: 0.55 -
0.77 mm
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![](../../../img/11/AK601670AB00ENG.png)
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1.Position each piston at
the TDC. 2.Check for piston protrusions of each
cylinder. There are five reference points A on
the upper crankcase assembly. For each cylinder, measure the
piston protrusion at the specified 4
points using the closest reference point as zero level.
Average the 4 point readings. B: Measuring point (16 in
total) 3.If the average deviates the specified
standard value, measure clearance at each section
of piston, connecting rod and
crankshaft.
Standard value: 0.07
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0.08 mm Limit: 0.15 mm
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![](../../../img/11/AK601670AB00ENG.png)
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1.Measure end play of each
connecting rod. 2.If the measurement exceeds the
specified service limit, replace defective
part.
Standard value: 0.15
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0.45 mm Limit: 0.6 mm
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![](../../../img/11/AK601708AA00ENG.png)
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caution |
- Be sure not to use the connecting rod
bearings expanded
forcedly.
- When either one of the connecting rod
bearings is replaced, replace both in
pairs.
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Measure free span of the connecting rod bearing s 4.
If the reading is less than the specified
service limit, replace both in
pairs.
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![](../../../img/11/AK601673AA00ENG.png)
![](../../../img/11/AK601674AB00ENG.png)
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Connecting Rod
Bearing-to-Crankshaft Clearance (Oil
Clearance)
If the reading exceeds the
specified service limit, replace defective
part.
Standard value:
0.03 -
0.05 mm Limit: 0.1 mm
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![](../../../img/11/AK601670AB00ENG.png)
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1.Measure the clearance
between the piston pin and piston. If the clearance exceeds
the
specified service limit, replace defective
part.
Standard value: 0.007
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0.021 mm Limit: 0.05 mm
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![](../../../img/11/AK601687AB00ENG.png)
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1.Place the piston rings in
the cylinder bore of the crankcase using the
piston. 2.Holding the piston rings in this state,
measure their end gap using a feeler gauge.
If the reading exceeds the specified service limit, replace
the piston ring.
Standard
value:
No.1 ring: 0.3 -
0.45 mm No.2 ring: 0.3 -
0.45 mm Oil ring: 0.25 -
0.45 mm
Limit:
No.1
ring: 0.8 mm No.2 ring: 0.8 mm Oil ring:
0.8 mm
caution |
- In order to insert the piston rings
level in
the cylinder bore F of the crankcase, be
sure to use the piston 9.
- The piston rings must be placed at the
less wearing bottom part of the
crankcase
cylinder bore F.
- Replace the piston rings in a complete
set.
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![](../../../img/11/AK601688AA00ENG.png)
![](../../../img/11/AK601689AB00ENG.png)
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1.If the specified service
limit is exceeded, replace defective part. 2.The
first compression ring is a full keystone ring.Press it
against the piston with
a straightedge and measure the side clearance using a feeler
gauge.
Standard
value:
No.1 ring: 0.03 -
0.08 mm No.2 ring: 0.07 -
0.10 mm Oil ring: 0.03 -
0.06 mm
Limit:
No.1
ring: 0.15 mm No.2 ring: 0.15 mm Oil ring:
0.15 mm
3.
caution |
- Remove deposited carbon from all the
piston
ring grooves in the piston before
measurements. Make side clearance
measurements over the entire
ring groove.
- Replace the piston rings in a complete
set.
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![](../../../img/11/AK601690AB00ENG.png)
![](../../../img/11/AK601691AB00ENG.png)
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1.Install the connecting rod
bush and piston pin into the connecting
rod. 2.Measure the bend A and twist B of the
connecting rod. If the readings exceed the specified
service limits, replace the connecting
rod.
A: Bend Standard value:
0.05 mm B: Twist Standard value: 0.05
mm
caution |
- Install the connecting rod to the
connecting
rod aligner with the upper and lower
connecting rod bearings
attached.
- Tighten the connecting rod cap by
specified procedure.
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