XY Powersports XY500UTV, Service Manual

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6. ENGINE REMOVAL; INSPECTION & INSTALLATION
6-26
Piston Ring Free End Gap and End Gap
● Before installing piston rings, use vernier caliper to
measure the free end gap of each ring, and then fit
ring into the cylinder.
● Use thickness gauge to measure each ring end gap,
if any ring has an excess end gap, replace the
piston ring.
Piston ring free end gap limit:
Top ring: 8.9mm
2
nd
ring: 9.5mm
Piston ring end gap limit:
Top Ring: 0.60mm
2
nd
ring: 0.60mm
Tool: Vernier caliper
Thickness gauge
Piston Pin and Pin Bore
● Use a bore gauge to measure the inner diameter of
piston pin bore.
● Use micrometer to measure outer diameter of piston
pin.
● If out of limit, replace both piston and piston pin.
Piston pin bore limit: 23.030mm
● Use micrometer to measure piston pin outer
diameter at three points
Piston pin outer diameter limit: 22.980mm
Tools: Bore gauge (18-35mm)
Micrometer (0-25mm)