Suzuki DF70A - Piston Pin and Conrod Inspection

1D-53 Power Unit Mechanical:
Piston ring end gap
Standard (1st): 0.15 – 0.30 mm (0.0059 – 0.0118 in.)
Standard (2nd): 0.30 – 0.45 mm (0.0118 – 0.0177 in.)
Service limit (1st): 0.70 mm (0.028 in.)
Service limit (2nd): 1.00 mm (0.039 in.)
Piston ring free end gap
Measure piston ring free end gap using vernier calipers.
If measurement exceeds service limit, replace piston
ring.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm))
Piston ring free end gap
Standard (1st): Approx. 9.9 mm (0.3898 in.)
Standard (2nd): Approx. 9.7 mm (0.3819 in.)
Service limit (1st): 7.9 mm (0.311 in.)
Service limit (2nd): 7.8 mm (0.307 in.)
Piston Pin and Conrod Inspection
Z9J0111406022
Piston Pin
Visual inspection
• Check piston pin, conrod small end bore and piston
pin hole for wear or damage.
If badly worn or damaged, replace component.
• Apply engine oil on piston pin so that the piston pin
can move smoothly in the piston pin hole.
If improper condition is found, replace the piston pin
and/or piston.
Piston pin clearance
Check the piston pin clearance in the conrod small end.
Replace the conrod if its small end is badly worn or
damaged or if clearance exceeds service limit.
Measure the following item:
Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))
(B): 09900–20605 (Dial calipers (10 – 34 mm))
Piston pin outside diameter
Standard: 17.995 – 18.000 mm (0.7085 – 0.7087 in.)
Service limit: 17.980 (0.7079 in.)
Piston pin hole diameter
Standard: 18.006 – 18.014 mm (0.7089 – 0.7092 in.)
Service limit: 18.030 (0.7098 in.)
Conrod small end bore
Standard: 18.003 – 18.011 mm (0.7088 – 0.7091 in.)
Pin clearance in piston pin hole
Standard: 0.006 – 0.019 mm (0.0002 – 0.0007 in.)
Service limit: 0.05 (0.0019 in.)
Pin clearance in conrod small end
Standard: 0.003 – 0.016 mm (0.0001 – 0.0006 in.)
Service limit: 0.05 (0.0020 in.)
1. Cylinder 2. Piston ring
1
2
(A)
I9J011140066-02
(A)
I9J011140067-02
(A)
I9J011140068-02
(B)
I9J011140069-02
(B)
I9J011140070-02
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