Yamaha ROADLINER XV19SW, Service Manual

Page: 258 / 444

CYLINDERS AND PISTONS
5-46
EAS24380
REMOVING THE PISTON
1. Remove:
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
CAUTION:
ECA13810
Do not use a hammer to drive the piston pin
out.
NOTE:
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
• For reference during installation, put an identi-
fication mark on each piston crown.
• Before removing the piston pin, deburr the pis-
ton pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “4”.
2. Remove:
• Top ring
• 2nd ring
• Oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
EAS24410
CHECKING THE CYLINDERS AND PISTONS
The following procedure applies to all of the cyl-
inders and pistons.
1. Check:
• Piston wall
• Cylinder wall
Vertical scratches
→
Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
• Piston-to-cylinder clearance
▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
3
2
1
Bore
100.000–100.010 mm (3.9370–
3.9374 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
“C” = maximum of D
1
–D
6
“T” = maximum of D
1
or D
2
- maximum of D
5
or D
6
“R” = maximum of D
1
, D
3
or D
5
- minimum of
D
2
, D
4
or D
6