3-15
3
Measuring Piston Pin, Connecting
Rod Small End, and Piston-Pin Bore
1. Measure the piston pin outside diameter at each
end and in the center. If measurement does not
meet specifications, the piston pin must be
replaced.
ATV-1070
2. Inspect and measure the connecting rod small end.
If the measurement exceeds specifications, the
connecting rod must be replaced (see Center
Crankcase Components in this section).
3. Insert an inside dial indicator into the piston-pin
bore. Take two measurements to ensure accuracy.
The diameter must not exceed specifications. If the
diameter exceeds specifications, the piston must
be replaced.
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 a
point 8 mm (0.3 in.) 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.
NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.
ATV-1085B
2. Install the compression rings (1 and 2) so the let-
ter(s) on the top surface of each ring faces the
dome of the piston. Rotate the rings until the ring
end gaps are on directly opposite sides of the pis-
ton according to the illustration.
NOTE: The chrome (silver) ring should be
installed in the top position.
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