6. CYLINDER/PISTON
6-1
TROUBLE SHOOTING ...........................6-1
SERVICE INFORMATION......................6-1
CYLINDER REMOVAL...........................6-2
PISTON REMOVAL ................................6-3
PISTON/PISTON RING INSPECTION
............ 6-3
PISTON RING INSTALLATION ................6-5
PISTON INSTALLATION ..........................6-6
CYLINDER INSTALLATION .....................6-6
TROUBLE SHOOTING
LOW COMPRESSION
1. Worn cylinder or piston rings.
EXCESSIVE SMOKE
1. Worn cylinder,piston or piston rings.
2. Improper installation of piston rings.
3. Scored or scratched piston or cylinder
wall.
OVERHEATING
1. Excessive carbon build-up on piston or
combustion chamber wall.
KNOCKING OR ABNORMAL NOISE
1. Worn piston or cylinder.
2. Excessive carbon build-up
SERVICE INFORNATION
GENERAL STRUCTIONS
XS125-K
ITEM
STANDARD CERVICE
LIMIT
Cylinder I.D.
56.495
~
56.515mm
56.52mm
Runout
0.05mm
0.05mm
Cylinder
Taper
0.05mm
0.05mm
Top
0.025
~
0.055mm
0.060mm
Piston ring to
ring groove
clearance
Second
0.015
~
0.040mm
0.045mm
Top
0.10
~
0.30mm
0.5mm
Second
0.10
~
0.30mm
0.5mm
Piston ring
End gap
Oil ring
0.30
~
0.90mm
Piston O.D.
56.485
~
56.505mm
56.48mm
Piston pin bore
15.002
~
15.008mm
15.05mm
Connecting rod small end I.D.
15.016
~
15.034mm
15.07mm
Piston pin O.D.
14.994
~
15.000mm
14.994mm
Top
0.97
~
0.99mm
1.460mm
Piston ring
thickness
Second
0.97
~
0.99mm
1.460mm
Piston
rings
groove
clearance
Cylinder to piston clearnace
0.005
~
0.015mm
0.11mm