4. Maintenance
USE AND MAINTENANCE MANUAL
CHAPTER 4
MAINTENANCE
2-Strokes - Edition 00 / 2023
119
4
A
C
b
a
B
1
2
A
B
Piston check
– Remove deposits from the piston crown “A” and piston ring
groove “B “;
– Check the piston skirt, replace if it has scratches and/or
cracks;
– Measure the diameter of the piston skirt using a micrometer
“1”;
– Measure the specific distance “2” from the lower edge, if it
does not comply with the specifications replace it.
Distance “2”
Piston diameter
17.5 mm (0.69 in)
53.957–53.972 mm
(2.1243–2.1249 in)
(XX 125 / XE 125 versions)
25 mm (0.98 in)
66.345-66.355 mm
(2.6120-2.6124 in)
(XX 250 version)
Cylinder check
– Remove carbon deposits using a rounded scraper;
Do not use a sharp instrument. Avoid scratching the
aluminum.
– Check the internal surface of the cylinder, if damaged,
grind or replace;
– Measure the cylinder bore “C” in parallel (A,B,C) to and at
right angles to the crankshaft (a,b). Then, find the average
of the measurements.
“C”
= Maximum Aa-Cb
“T”
= (Maximum Aa, or Ab) – (Maximum Ba, or Bb)
Standard
Wear limit
Cylinder bore “C”
(XX 125 version)
54.000–54.014 mm
(2.1260–2.1265 in)
54.064 mm
(2.1285 in)
Cylinder bore “C”
(XE 125 version)
54.000–54.014 mm
(2.1260–2.1265 in)
54.100 mm
(2.1299 in)
Cylinder bore “C”
(XX 250 version)
66.400-66.414mm
(2.6142-2.6147 in)
66.464 mm
(2.6167 in)
Taper “T”
–
0.050 mm
(0.0020 in)
