Suzuki SFV650 - Piston and Piston Ring Inspection

Engine Mechanical: 1D-56
2) Position the gaps of the three rings and side rails as
shown. Before inserting piston into the cylinder,
check that the gaps are so located.
3) Install the piston and piston pin. Refer to “Engine Top
Side Assembly (Page 1D-31)”.
Piston and Piston Ring Inspection
B944H11406023
Refer to “Piston Ring Removal and Installation
(Page 1D-55)”.
Piston Diameter
Measure the piston diameter using the micrometer at 20
mm (0.8 in) “a” from the skirt end. If the piston diameter
is less than the service limit, replace the piston.
Special tool
(A): 09900–20204 (Micrometer (75 – 100 mm))
Piston diameter
Service limit: 80.880 mm (3.1842 in)
Piston-to-cylinder Clearance
Subtract the piston diameter from the cylinder bore
diameter. If the piston-to-cylinder clearance exceeds the
service limit, replace both the cylinder and the piston.
Piston-to-cylinder clearance
Service limit: 0.120 mm (0.0047 in)
Piston Ring-to-groove Clearance
Measure the side clearances of the 1st and 2nd piston
rings using the thickness gauge. If any of the clearances
exceed the limit, replace both the piston and piston
rings.
Special tool
(A): 09900–20803 (Thickness gauge)
(B): 09900–20205 (Micrometer (0 – 25 mm))
Piston ring-to-groove clearance
Service limit: (1st): 0.180 mm (0.0071 in)
Service limit: (2nd): 0.150 mm (0.0059 in)
Piston ring groove width
“a”: Standard: (1st): 0.83 – 0.85 mm (0.0327 – 0.0335
in)
“b”: Standard: (1st): 1.30 – 1.32 mm (0.0512 – 0.0520
in)
“c”: Standard: (2nd): 1.01 – 1.03 mm (0.0398 – 0.0406
in)
“d”: Standard: (Oil): 2.01 – 2.03 mm (0.0791 – 0.0799
in)
Piston ring thickness
Standard: (1st): 0.76 – 0.81 mm (0.0299 – 0.0319 in)
Standard: (1st): 1.08 – 1.10 mm (0.0425 – 0.0433 in)
Standard: (2nd): 0.97 – 0.99 mm (0.0382 – 0.0390 in)
“C”: 2nd ring and lower side rail
“D”: Upper side rail
“E”: 1st ring and spacer
EX
IN
“C”
“D”
“E”
I944H1140351-01
“a”
I944H1140249-01
(A)
I944H1140250-01
(A)
I649G1140263-03
“a”
“b”
“c”
“d”
I944H1140349-01