11-1
11. CYLINDER / PISTON
SERVICE INFORMATION
GENERAL SAFETY
●
Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the
cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the
cylinder fins.
●
Take care not to damage the cylinder wall and piston.
●
Check parts after disassembling, and clean and dry with an air hose prior to taking measurements.
SPECIFICATIONS
11
SERVICE INFORMATION
·
··
··
·
11-1
TROUBLESHOOTING
·
··
··
··
··
·
11-1
CYLINDER REMOVAL
·
··
··
··
··
·
11-2
PISTON REMOVAL
·
··
··
··
··
··
·
11-2
PISTON RING INSTALLATION
·
·
11-5
PISTON INSTALLATION
·
··
··
··
·
11-6
CYLINDER INSTALLATION
·
··
·
11-6
ITEM
STANDARD (mm)
SERVICE LIMIT (mm)
CYLINDER
PISTON,
PISTON RING
PISTON PIN O.D
PISTON-TO-PISTON PIN CLEARANCE
CONNECTING ROD SMALL END I.D. BORE
I.D.
WARPAGE
CYLINDRICITY
TRUE ROUNDNESS
RING-TO-GROOVE TOP
CLEARANCE SECOND
TOP
RING END GAP SECOND
OIL RING
PISTON O.D.
PISTON-TO-CYLINDER CLEARANCE
PISTON PIN HOLE I.D
72.705~72.715
0.01
0.01
0.01
0.2
0.015~0.050
0.1~0.25
0.15~0.30
0.25~0.7
72.67~72.69
0.010~0.040
17.002~17.008
16.994~17.000
0.002~0.014
17.016~17.034
72.80
0.05
0.05
0.05
0.09
0.09
0.50
0.50
-
72.6
0.01
17.04
16.96
0.02
17.06
TROUBLESHOOTING
●
When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white
smoke is found, it means that the piston rings are worn, stuck or broken.
Comperssion too low or uneven compression
Excessive smoke from exhaust muffler
●
Worn or damaged cylinder and piston ring
●
Worn or damaged piston rings
●
Worn, stuck or broken piston rings
●
Worn or damaged cylinder and piston
Comperssion too high
Abnormal noise piston
●
Excessive carbon build-up in combustion
●
Worn cylinder, piston and piston rings
●
chamber or on piston head
●
Worn piston pin hole and piston pin
●
Incorrectly installed piston
Summary of Contents for S2-250
Page 1: ......
Page 3: ......
Page 23: ...MEMO...
Page 35: ...MEMO...
Page 44: ...MEMO...
Page 45: ...4 0 LUBRICATION SYSTEM ROCKER ARM SHAFT CRANK SHAFT OIL FILTER SCREEN OIL PUMP...
Page 52: ...MEMO...
Page 53: ...5 0 FUEL SYSTEM...
Page 66: ...MEMO...
Page 67: ...6 0 COOLING SYSTEM...
Page 81: ...MEMO...
Page 86: ...MEMO...
Page 87: ...8 0 LH CRANKCASECOVER CONTINUOUSLYVARIABLE TRANSMISSION...
Page 100: ...MEMO...
Page 101: ...9 0 A C GENERATOR STARTER CLUTCH...
Page 107: ...10 0 CYLINDER HEAD VALVE...
Page 116: ...MEMO...
Page 117: ...11 0 CYLINDER PISTON...
Page 125: ...12 0 CRANKSHAFT CRANKCASE...
Page 132: ...MEMO...
Page 133: ...13 0 FINAL REDUCTION...
Page 139: ...14 0 FRONT WHEEL FRONT FORK STEERING BRAKE...
Page 160: ...MEMO...
Page 161: ...15 0 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...
Page 169: ...16 0 CHARGING SYSTEM REGULATOR RECTIFIER MAIN SWITCH A C GENERATOR...
Page 180: ...MEMO...
Page 188: ...MEMO...
Page 189: ...MEMO...
Page 197: ...MEMO...
Page 199: ...MEMO...
Page 200: ...SERVICEMANUAL 2004 9 PRINTED 2004 9 PUBLICATION NO COPY...