Service manual

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Piston pin clip removal and
installation
TIP:
Before removing or installing the piston pin
clip, cover the crankcase opening with a
clean rag to prevent the piston pin clip from
falling into the crankcase.
Piston check
1. Eliminate the carbon deposits (from the
piston crown and piston ring grooves).
2. Check the piston wall. Repair using 600–
800 grit wet sandpaper or replace if there
are score marks.
TIP:
Lightly sand the piston wall in a crisscross
pattern.
3. Measure the piston skirt diameter.
Replace if out of specification.
Piston ring check
1. Measure the side clearance (using a
thickness gauge 1). Replace the piston
and piston rings as a set if out of specifi-
cation.
2. Measure the end gap (using a thickness
gauge 1). Replace the piston rings as a
set if out of specification.
TIP:
Push the piston ring into the cylinder with the
piston crown.
Piston diameter Distance a
80.922–80.941 mm
(3.1859–3.1866 in)
10 mm (0.39 in)
Piston-to-cylinder clearance:
0.080–0.085 mm (0.0031–0.0033 in)
Side clearance:
0.03–0.05 mm (0.001–0.002 in)
End gap: 0.20–0.40 mm (0.008–0.015 in)
Pistons