Suzuki AN650 2002 - Piston and Piston Ring

3-36 ENGINE
PISTON AND PISTON RING
PISTON DIAMETER
• Using a micrometer, measure the piston outside diameter at
15 mm (0.6 in) from the piston skirt end.
• If the measurement is less than the limit, replace the piston.
 Piston diameter:
Standard: 75.450 – 75.465 mm (2.9704 – 2.9710 in)
Service Limit: 75.380 mm (2.9677 in)
at 15 mm (0.6 in) from the skirt end
[ 09900-20204: Micrometer (75 – 100 mm)
PISTON TO CYLINDER CLEARANCE
• Subtract the piston diameter from the cylinder bore diameter.
• If the piston to cylinder clearance exceeds the service limit,
replace the cylinder and the piston.
 Piston to cylinder clearance:
Standard: 0.045 – 0.055 mm (0.00177 – 0.00216 in)
Service Limit: 0.120 mm (0.0047 in)
PISTON PINS AND PIN BORE
• Measure the piston pin bore inside diameter using the small
bore gauge.
• If the measurement is out of specification, replace the piston.
[ 09900-20602: Dial gauge (1/1000 mm)
09900-22401: Small bore gauge (10 – 18 mm)
 Piston pin bore I.D.:
Service Limit: 16.030 mm (0.6311 in)
• Measure the piston pin outside diameter at three positions
using the micrometer.
• If any of the measurements are out of specification, replace
the piston pin.
[ 09900-20205: Micrometer (0 – 25 mm)
 Piston pin O.D.:
Service Limit: 15.980 mm (0.6291 in)
15 mm (0.6 in)