9. CYLINDER/PISTON
9-2
MXU 500
SERVICE INFORMATION
GENERAL INSTRUCTIONS
xThe cylinder and piston can be serviced with the engine installed in the frame.
xWhen installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are
correctly installed.
xAfter disassembly, clean the removed parts and dry them with compressed air before inspection.
SPECIFICATIONS Unit: mm (in)
Ite
Service Limit
I.D. 92.005 (3.6802)阡92.015 (3.6806) 92.1 (3.684)
Warpage
0.01 (0.0004)
0.05 (0.002)
Cylindricity
0.01 (0.0004)
0.1 (0.004)
True roundness
0.01 (0.0004)
0.1 (0.004)
Ring-to-groove top
0.03 (0.0012)阡0.065 (0.0026) 0.08 (0.003)
clearance
Second
0.015 (0.0006)阡0.05 (0.002) 0.065 (0.0026)
top
0.15 (0.006)阡0.3 (0.012) 0.5 (0.02)
Piston, Ring end gap Second
0.03 (0.012)阡0.45 (0.018) 0.65 (0.026)
piston ring Oil side rail
0.2 (0.008)阡0.7 (0.028)
1 (0.04)
Piston O.D.
91.96 (3.6784)阡91.98 (3.6793) 91.9 (3.676)
Piston O.D. measuring position
10 mm from bottom of skirt －
. Piston-to-cylinder clearance
0.01 (0.0004)阡0.045 (0.0018) 0.1 (0.004)
Piston pin hole I.D.
22.002 (0.8801)阡22.008 (0.8803) 22.04 (0.8816)
Piston pin O.D
21.994 (0.8798)阡22 (0.88) 21.96 (0.8784)
Piston-to-piston pin clearance
0.002 (0.0001)阡0.014 (0.0006) 0.02 (0.001)
Connecting rod small end I.D. bore
22.016 (0.8806)阡22.034 (0.8814) 22.06 (0.8824)
TORQUE VALUES
Cylinder bolt 1 kgf-m (10 N-m, 7.2 lbf-ft)
TROUBLESHOOTING
xWhen hard starting or poor performance at low speed occurs, check the crankcase breather for
white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.
Compression too low or uneven
compression Excessive smoke from exhaust muffler
xWorn or damaged cylinder and piston rings x Worn or damaged piston rings
xWorn, stuck or broken piston rings x Worn or damaged cylinder and piston
Compression too high Abnormal noisy piston
xExcessive carbon build-up in combustion x Worn cylinder, piston and piston rings
chamber or on piston head x Worn piston pin hole and piston pin
x Incorrectly installed piston
Cylinde
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