7. CYLINDER/PISTON
10-2
G-Dink 300i
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
I.D.
72.75 (2.91)
~
72.7015 (2.90806)
72.8 (2.912)
Warpage
0.01 (0.0004)
0.05 (0.002)
Cylindricity
0.01 (0.0004)
0.1 (0.004)
True roundness
0.01 (0.0004)
0.1 (0.004)
Ring-to-groove
top
0.03 (0.0012)
~
0.065 (0.0026)
0.08 (0.003)
clearance
Second
0.015 (0.0006)
~
0.05 (0.002)
0.65 (0.0026)
top
0.15 (0.006)
~
0.3 (0.012)
0.5 (0.02)
Piston,
Ring end gap
Second
0.03 (0.012)
~
0.45 (0.018)
0.65 (0.026)
piston ring
Oil side rail
0.2 (0.008)
~
0.7 (0.028)
1 (0.04)
Piston
O.D.
72.67 (2.9068)
~
72.69 (2.9076)
72.6 (2.904)
Piston O.D. measuring position
9 mm from bottom of skirt
-
. Piston-to-cylinder
clearance
0.01 (0.0004)
~
0.045 (0.0018)
0.1 (0.004)
Piston pin hole I.D.
17.002 (0.68008)
~
17.008 (0.68032) 17.04 (0.6816)
Piston pin O.D
16.994 (0.67976)
~
17 (0.68)
16.96 (0.6784)
Piston-to-piston pin clearance
0.002 (0.0001)
~
0.014 (0.0006)
0.02 (0.001)
Connecting rod small end I.D. bore
17.016 (0.68064)
~
17.034 (0.68136) 17.06 (0.6824)
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.
Compression too low or uneven
compression
Excessive smoke from exhaust muffler
•
Worn or damaged cylinder and piston rings
•
Worn or damaged piston rings
•
Worn, stuck or broken piston rings
•
Worn or damaged cylinder and piston
Compression too high
Abnormal noisy 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
Cylinder
7-2
Summary of Contents for G-DINK 300i
Page 4: ...1 GENERAL INFORMATION 1 1 G DINK 300i Identification Numbers Record ...
Page 11: ...1 GENERAL INFORMATION 1 8 G DINK 300i TORQUE VALUES ...
Page 12: ...1 GENERAL INFORMATION 1 9 G DINK 300i TORQUE VALUES ...
Page 13: ...1 GENERAL INFORMATION 1 10 G DINK 300i TORQUE VALUES FRAME ...
Page 43: ...3 INSPECTION ADJUSTMENT 3 2 G DINK 300i MAINTENANCE SCHEDULE ...
Page 55: ...4 LUBRICATION SYSTEM 4 1 G DINK 300i LUBRICATION ...
Page 72: ...6 CYLINDER HEAD VALVES 9 1 G Dink 300i 6 1 ...
Page 89: ...7 CYLINDER PISTON 10 1 G Dink 300i SCHEMATIC DRAWING 7 1 ...
Page 114: ...9 FINAL REDUCTION 9 1 G DINK 300i SCHEMATIC DRAWING ...
Page 123: ...10 A C GENERATOR STARTER CLUTCH 10 1 G Dink300i SCHEMATIC DRAWING ...
Page 130: ...11 CRANKCASE CRANKSHAFT 11 1 G DINK 300i SCHEMATIC DRAWING ...
Page 138: ...12 COOLING SYSTEM 12 1 G DINK 300i SCHEMATIC DRAWING ...
Page 210: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 G DINK 300i SCHEMATIC DRAWING ...
Page 217: ...15 REAR WHEEL REAR BRAKE REAR SUSPENSION G DINK 300i 15 8 ...