G120F/G160F/G200F Part IV Disassembly and maintenance
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Timing mark alignment
Align the punch marks on the camshaft gear and
timing gear (smaller gear on the crankshaft) when
installing camshaft.
3. Inspection
Piston inspection
Check the contact between piston and cylinder,
defects of ring grooves, ablation and cracks on
piston top, etc. replace the piston if the damage
is severe.
Removal of carbon deposits
Carbon deposits accumulate on piston top and
upper edge of cylinder. Remove carbon deposits
completely before inspection. Saturate the carbon
deposits with kerosene and then use a blunt scraper
or a wire brush to remove carbon deposits.
1) Piston skirt O.D.
measure and record the piston O.D. using an outside
micrometer at a point 10mm (0.4in) from the bottom
of the skirt 90° to the piston pin bore. Replace it if
its size exceeds service limit.
Standard Service limit
G120
59.985mm 59.845 mm
G160 200
67.985mm 67.845 mm
2) Piston-to-cylinder clearance
The difference between the cylinder bore’s maximum diameter and piston skirt’s outer diameter
is the piston-to-cylinder clearance.
Standard Service limit
0.015-0.050mm 0.12mm
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