BRP Outlander 400 EFI 2008, Service Manual

Page: 139 / 434

Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)
The measured dimension should be as described
in the following table. If not, replace piston.
PISTON MEASUREMENT
NEW
90.950 to 90.966 mm
(3.5807 to 3.5813 in)
SERVICE LIMIT 90.850 mm (3.577 in)
Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimen-
sion.
F00B08A
1
1. Micrometer set to the piston dimension
With the micrometer set to the dimension, adjust
a cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero).
F00B09A
1
2
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
F00B0AA
1
TYPICAL
1. Indicator set to 0 (zero)
Position the dial bore gauge 20 mm (.787 in) above
cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
PISTON/CYLINDER CLEARANCE
NEW
0.027 to 0.057 mm
(.0011 to .0022 in)
SERVICE LIMIT 0.010 mm (.004 in)
NOTE: Make sure used piston is not worn. See
PISTON MEASUREMENT above.
If clearance exceeds specified tolerance, replace
cylinder.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Piston Pin
Using synthetic abrasive woven, clean piston pin
no. 38 from deposits.
Inspect piston pin for scoring, cracking or other
damages.
Measure piston pin. See the following illustration
for the proper measurement position.
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