Yamaha STAR XVS95CE 1TP1 2014, Service Manual

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CYLINDERS AND PISTONS
5-37
EAS24380
REMOVING THE PISTONS
The following procedure applies to all of the pis-
tons.
1. Remove:
• Circlips “1”
• Piston pin “2”
• Piston “3”
NOTICE
ECA13810
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the circlips, cover the crank-
case opening with a clean rag to prevent the
circlips from falling into the crankcase.
• Before removing the piston pin, deburr the cir-
clips’ 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
TIP
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 the cylinder bore with the cylinder
bore gauge.
TIP
Measure the cylinder bore 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
Bore
85.000–85.010 mm (3.3465–
3.3468 in)
Wear limit
85.100 mm (3.3504 in)
Out of round limit
0.050 mm (0.0020 in)
Bore = maximum of D
1
–D
4
Wear limit = maximum of D
1
or D
3
Out of round limit = maximum of D
1
or D
3
-
minimum of D
2
or D
4