Bad Boy 1500 - Troubleshooting

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Precautions in Operation:
Standard Limit
ID 86.022-86.052 86.100
Warpage / 0.050
Top Ring 0.04-0.075 0.011
2nd Ring 0.02-0.055 0.090
Top Ring 0.150-0.300 0.500
2nd Ring 0.300-0.450 0.650
Oil ring side rail 0.200-0.700 /
85.30-85.50 85.25
0.04-0.058 0.120
20.001-20.006 20.020
19.996-20.000 19.960
0.001-0.010 0.020
20.002-20.01 20.040
OD of piston pin
Clearance between piston and piston pin
ID of connecting rod small-end
OD of piston (2nd)
Clearance between piston and cylinder
ID of piston pin boss
Item
Cylinder
Piston/ Piston Ring
Clearance between piston rings
Ring-end gap
Troubleshooting:
Low or Unstable Compression Pressure
• Cylinder or piston ring worn out
Knock or Noise
• Cylinder or piston ring wear
• Carbon deposits on cylinder head top-side
• Piston pin bore and piston pin wear
Smoking in Exhaust Pipe
• Piston or piston ring wear
• Piston ring improper installation
• Cylinder or piston damage
Engine Overheat
• Carbon deposits on cylinder head top side
• Cooling pipe clogged or not enough coolant flow