Suzuki DF 90 - Page 563

DF90/115/140 “K8” (’08) MODEL 18-9
CYLINDER / PISTON / PISTON RING
Item Unit
Data
DF90T DF115T/115WT
Cylinder distortion Limit mm (in) 0.05 (0.002)
Piston to cylinder
clearance
STD mm (in) 0.020 – 0.040 (0.0008 – 0.0016)
Limit mm (in) 0.100 (0.0039)
Cylinder bore STD mm (in) 84.000 – 84.020 (3.3071 – 3.3079)
Cylinder measuring position mm (in) 50 (2.0) from cylinder top surface
Piston skirt diameter STD mm (in) 83.970 – 83.990 (3.3059 – 3.3067)
Piston measuring position mm (in) 26.5 (1.04) from piston skirt end
Cylinder bore wear Limit mm (in) 0.100 (0.0039)
Piston ring
end gap
1st
STD mm (in) 0.20 – 0.35 (0.008 – 0.014)
Limit mm (in) 0.70 (0.028)
2nd
STD mm (in) 0.35 – 0.50 (0.014 – 0.020)
Limit mm (in) 1.00 (0.039)
Piston ring
free end gap
1st
STD mm (in) Approx. 11.3 (0.44)
Limit mm (in) 9.0 (0.354)
2nd
STD mm (in) Approx. 11.0 (0.43)
Limit mm (in) 8.8 (0.347)
Piston ring to
groove clearance
1st
STD mm (in) 0.030 – 0.070 (0.0012 – 0.0028)
Limit mm (in) 0.120 (0.0047)
2nd
STD mm (in) 0.020 – 0.060 (0.0008 – 0.0024)
Limit mm (in) 0.100 (0.0039)
Piston ring
groove width
1st STD mm (in) 1.22 – 1.24 (0.048 – 0.049)
2nd STD mm (in) 1.51 – 1.53 (0.059 – 0.060)
Oil STD mm (in) 2.51 – 2.53 (0.099 – 0.100)
Piston ring
thickness
1st STD mm (in) 1.17 – 1.19 (0.046 – 0.047)
2nd STD mm (in) 1.47 – 1.49 (0.058 – 0.059)
Pin clearance in
piston pin hole
STD mm (in) 0.006 – 0.017 (0.0002 – 0.0007)
Limit mm (in) 0.040 (0.0016)
Piston pin outside
diameter
STD mm (in) 20.997 – 21.000 (0.8267 – 0.8268)
Limit mm (in) 20.980 (0.8260)
Piston pin hole
diameter
STD mm (in) 21.006 – 21.014 (0.8270 – 0.8273)
Limit mm (in) 21.040 (0.8283)
Pin clearance in
conrod small end
STD mm (in) 0.003 – 0.014 (0.0001 – 0.0006)
Limit mm (in) 0.050 (0.0020)
Conrod small end
bore
STD mm (in) 21.003 – 21.011 (0.8269 – 0.8272)