Kolpin Powersports 180??, Service Manual

Page: 61 / 87

59
FIG-18. Engine Disassembly
CYLINDER AND PISTON
PISTON / PISTON RING INSPECTION
Calculate the piston-to-piston pin clearance.
(Photo 63)
SERVICE LIMITS: 0.02 mm
Measure the connecting rod small end I.D.
(Photo 64)
SERVICE LIMITS: 15.06 mm
PISTON &PISTON RING INSTALLATION
Clean the piston ring grooves thoroughly and install the
piston ring with the marks facing up.
NOTE: Don’t interchange the top and second rings to
avoid piston and piston ring damage during installation.
Space the piston ring end gaps 120 degrees apart
(Photo 65)
PISTON INSTALLATION
Install the piston with it’s “IN” mark on the intake valve
(Photo 66)
Install the piston pin with new pin clips.
Do not align the piston pin clip end gap with the piston
cutout.
(Photo 67)
NOTE: do not allow the clip to fall into the crankcase.