Yamaha XJR1300 2007, Service Manual

Page: 200 / 386

CYLINDER AND PISTON
5-27
EAS24440
CHECKING THE PISTON PIN
1. Check:
●
Piston pin
Blue discoloration/grooves
→
Replace the
piston pin and then check the lubrication sys-
tem.
2. Measure:
●
Piston pin outside diameter “a”
Out of specification
→
Replace the piston pin.
3. Measure:
●
Piston pin bore diameter “b”
Out of specification
→
Replace the piston.
4. Calculate:
●
Piston-pin-to-piston-pin-bore clearance
Out of specification
→
Replace the piston pin
and piston as a set.
EAS24470
INSTALLING THE PISTON AND CYLINDER
1. Install:
●
Top ring “1”
●
2nd ring “2”
●
Lower oil ring rail “3”
●
Upper oil ring rail “4”
●
Oil ring expander “5”
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks face up.
piston ring end gap
Top ring
End gap (installed)
0.20 – 0.35 mm (0.0079 – 0.0138 in)
Limit
0.60 mm (0.0236 in)
2nd ring
End gap (installed)
0.35 – 0.50 mm (0.0138 – 0.0197 in)
Limit
0.75 mm (0.0295 in)
Oil ring
End gap (installed)
0.20 – 0.50 mm (0.0079 – 0.0197 in)
Piston pin outside diameter
17.991 – 18.000 mm
(0.7083 – 0.7087 in)
Limit
17.971 mm (0.7075 in)
Piston pin bore inside diameter
18.004 – 18.015 mm
(0.7088 – 0.7093 in)
Limit
18.045 mm (0.7104 in)
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter “b” -
Piston pin outside diameter “a”
Piston pin/piston pin hole clear-
ance
0.004 – 0.024 mm
(0.00016 – 0.00094 in)