3-60
ATV-1069
Measuring Piston Skirt/
Cylinder Clearance
1. Measure the cylinder front to back in six places.
CC127D
2. Measure the corresponding piston diameter at the
recommended point above the piston skirt at a
right angle to the piston-pin bore. Subtract this
measurement from the measurement in step 1. The
difference (clearance) must be within specifica-
tions.
Installing Piston Rings
1. Install ring expander (4) in the bottom groove of
the piston; then install the thin oil rings (3) over
the expander making sure the expander ends do
not overlap. Stagger the end gaps of the upper and
lower thin oil rings according to the illustration.
ATV-1085B
NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.
2. The ring with the orientation mark (MTOP or
TOP) should be installed in the second (middle)
groove and the ring with the orientation mark (M
or O) should be installed in the first (top) groove.
ATV-1024A
ATV-1024B
CYLINDER/CYLINDER HEAD
ASSEMBLY
NOTE: If the cylinder/cylinder head assembly
cannot be trued, they must be replaced.
Cleaning/Inspecting Cylinder Head
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber
being careful not to nick, scrape, or damage the
combustion chamber or the sealing surface.
2. Inspect the spark plug hole for any damaged
threads. Repair damaged threads using a
“heli-coil” insert.
CAUTION
Incorrect installation of the piston rings will result in
engine damage.
CAUTION
The cylinder head studs must be removed for this pro-
cedure.
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