Suzuki DF 40, Service Manual

Page: 334 / 405

DF40/50 “K6” (’06) MODEL 9
CYLINDER/PISTON/PISTON RING
Item Unit
Data
DF40 DF50
Cylinder distortion Limit mm (in) 0.060 (0.0024)
Piston to cylinder clearance STD mm (in) 0.020 – 0.040 (0.0008 – 0.0016)
Limit mm (in) 0.100 (0.0039)
Cylinder bore STD mm (in) 71.000 – 71.020 (2.7953 – 2.7961)
Cylinder measuring position mm (in) 50 (2.0) from cylinder top surface
Piston skirt diameter STD mm (in) 70.970 – 70.990 (2.7941 – 2.7949)
Piston measuring position mm (in) 19 (0.7) from piston skirt end
Cylinder bore wear Limit mm (in) 0.100 (0.0039)
Piston ring end gap
1st
STD mm (in) 0.10 – 0.25 (0.004 – 0.010)
Limit mm (in) 0.70 (0.028)
2nd
STD mm (in) 0.25 – 0.40 (0.010 – 0.016)
Limit mm (in) 1.00 (0.039)
Piston ring free end
gap
1st
STD mm (in) Approx. 7.5 (0.30)
Limit mm (in) 6.0 (0.24)
2nd
STD mm (in) Approx. 11.0 (0.43)
Limit mm (in) 8.8 (0.35)
Piston ring to groove
clearance
1st
STD mm (in) 0.02 – 0.06 (0.001 – 0.002)
Limit mm (in) 0.10 (0.004)
2nd
STD mm (in) 0.02 – 0.06 (0.001 – 0.002)
Limit mm (in) 0.10 (0.004)
Piston ring groove
width 1st STD mm (in) 1.01 – 1.03 (0.040 – 0.041)
2nd STD mm (in) 1.01 – 1.03 (0.040 – 0.041)
Oil STD mm (in) 2.01 – 2.03 (0.079 – 0.080)
Piston ring thickness 1st STD mm (in) 0.97 – 0.99 (0.038 – 0.039)
2nd STD mm (in) 0.97 – 0.99 (0.038 – 0.039)
Pin clearance in piston pin
hole STD mm (in) 0.006 – 0.018 (0.0002 – 0.0007)
Limit mm (in) 0.040 (0.0016)
Piston pin outside diameter STD mm (in) 17.996 – 18.000 (0.7085 – 0.7087)
Limit mm (in) 17.980 (0.7079)
Piston pin hole diameter STD mm (in) 18.006 – 18.014 (0.7089 – 0.7092)
Limit mm (in) 18.040 (0.7102)
Pin clearance in conrod
small end STD mm (in) 0.003 – 0.015 (0.0001 – 0.0006)
Limit mm (in) 0.050 (0.0020)
Conrod small end bore STD mm (in) 18.003 – 18.011 (0.7088 – 0.7091)