Yamaha 2009 XP500Y TMAX, Service Manual

Page: 217 / 386

CYLINDER AND PISTONS
5-28
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter D “a” with the
micrometer.
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
f. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
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EAS24430
CHECKING THE PISTON RINGS
1. Measure:
• Piston ring side clearance
Out of specification
→
Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
2. Install:
• Piston ring
(into the cylinder)
TIP
Level the piston ring into the cylinder with the
piston crown.
b. 9.0 mm (0.35 in) from the bottom edge of the
piston
Piston
Diameter D
65.965–65.980 mm (2.5970–
2.5976 in)
• Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.020–0.045 mm (0.0008–0.0018
in)
Limit
0.15 mm (0.0059 in)
Piston ring
Top ring
Ring side clearance
0.030–0.065 mm (0.0012–
0.0026 in)
2nd ring
Limit
0.100 mm (0.0039 in)
Ring side clearance
0.020–0.055 mm (0.0008–
0.0022 in)
Limit
0.100 mm (0.0039 in)
a. 10 mm (0.39 in)