KYMCO 125 DINK -, Service Manual

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7
. CYLINDER/PISTON
7-2
DINK 200i/125
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The cylinder and piston can be serviced with the engine installed in the frame.
When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are
correctly installed.
After disassembly, clean the removed parts and dry them with compressed air before inspection.
SPECIFICATIONS
Unit: mm (in)
Item
Standard Service Limit
DINK 200i
62
Д
62.015 (2.48
Д
2.4806) 62.1 (2.484)
I.D.
DINK 125
52.4
Д
52.41 (2.096
Д
2.0964) 52.5 (2.1)
Warpage !
0.05 (0.002)
Cylindricity !
0.05 (0.002)
Cylinder
True roundness !
0.05 (0.002)
Ring-to-groove Top 0.015
Д
0.05 (0.006
Д
0.002) 0.09 (0.0036)
clearance
Second 0.015
Д
0.05 (0.006
Д
0.002) 0.09 (0.0036)
Top 0.15
Д
0.3 (0.006
Д
0.012) 0.5 (0.02)
Ring end gap Second 0.15
Д
0.3 (0.006
Д
0.012) 0.5 (0.02)
Oil side rail 0.2
Д
0.9 (0.008
Д
0.036)
!
DINK 200i 61.995
Д
61.975 (2.4878
Д
2.479) 61.9 (2.476)
Piston O.D.
DINK 125
52.37
Д
52.39 (2.0948
Д
2.0956) 52.3 (2.092)
DINK 200i
5 mm (0.2 in) from bottom of skirt
!
Piston O.D.
measuring
position
DINK 125
9 mm (0.36 in) from bottom of skirt
!
Piston-to-cylinder clearance 0.01
Д
0.04 (0.0004
Д
0.0016) 0.1 (0.004)
Piston,
piston ring
Piston pin hole I.D.
15.002
Д
15.008 (0.60008
Д
0.60032) 15.04 (0.6016)
Piston pin O.D 14.994
Д
15 (0.59976
Д
0.6) 14.96 (0.5984)
Piston-to-piston pin clearance
0.002
Д
0.014 (0.00008
Д
0.00056) 0.02 (0.0008)
Connecting rod small end I.D. bore 15.016
Д
15.034 (0.60064
Д
0.60136) 15.06 (0.6024)