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SERVICE MANUAL
Cylinder / Piston
Cylinder & Piston Removal:
• Remove cylinder head (refer to chapter 6).
• Remove coolant hose from cylinder.
• Remove cylinder.
• Cover the holes of crankcase and cam chain with a
piece of cloth.
• Remove piston pin clip, and then remove piston pin
and piston.
• Remove cylinder gasket and dowel pin.
• Clean up all residue or foreign materials from the
two matching surfaces of cylinder and crankcase.
CAUTION
•Soak gaskets in solvent so that the residue can be
removed more easily.
Inspection:
• Check the inner diameter of
cylinder for wear or damage.
• In the 3 positions: top, center
and bottom of cylinder,
measure the X and Y values
in the cylinder.
Service limit: 86.100 mm
Cylinder & Piston Removal:
• Check cylinder for warping.
• Service limit: 0.05 mm
• Measure clearance between piston rings and
grooves.
• Service Limit: Top ring: 0.09 mm
2nd ring: 0.09 mm
CAUTION
• Be careful removing piston rings because they
are fragile.
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