44
CC400D
2. Remove each ring by working it toward the top of
the piston while rotating it out of the groove.
NOTE: When installing new rings, install as a com-
plete set only.
Cleaning/Inspecting Piston Ring
Grooves
1. Take an old piston ring and snap it into two pieces;
then grind the end of the old ring to a 45° angle and
to a sharp edge.
2. Using the sharpened ring as a tool, clean carbon from
the ring grooves. Be sure to position the ring with its
tapered side up.
Measuring Piston-Ring End Gap
(Installed)
1. Place each piston ring in the wear portion of the cyl-
inder. Use the piston to position each ring squarely in
the cylinder.
2. Using a feeler gauge, measure each piston-ring end
gap. Acceptable ring end gap must be within specifi-
cations.
CC995
Measuring Piston Pin, Connecting
Rod Small End, and Piston-Pin Bore
1. Measure the piston pin outside diameter at each end
and in the center. If measurement exceeds specifica-
tions, the piston pin must be replaced.
ATV-1070
2. Inspect and measure the connecting rod small end. If
the measurement exceeds specifications, the con-
necting rod must be replaced (see Center Crankcase
Components in this section).
3. Insert an inside dial indicator into the piston-pin
bore. Take two measurements to ensure accuracy.
The diameter must not exceed specifications. If the
diameter exceeds specifications, the piston must be
replaced.
ATV-1069
Measuring Piston Skirt/Cylinder
Clearance
1. Measure the cylinder front to back in six places.
CC397D
2. Measure the corresponding piston diameter at a point
15 mm above the piston skirt at a right angle to the
piston-pin bore. Subtract this measurement from the
measurement in step 1. The difference (clearance)
must be within specifications.
CAUTION
Improper cleaning of the ring grooves by the use of the
wrong type of ring groove cleaner will result in severe
damage to the piston.
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