3-37
ENG
PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE
a
b
a
P
CYLINDER INSPECTION
1. Measure:
9
Cylinder inside diameter
TIP
Take side to side
a
and front to back
b
mea-
surements at each of the three locations A, B,
C (total of six measurements), and then find
the average of the measurements.
Out of specification
→
Replace the
crankcase.
2. Measure:
9
Cylinder warpage
TIP
Measure the warpage on the contact surface
of the cylinder head at six points using a
straight edge and thickness gauge.
Out of specification
→
Replace.
PISTON AND PISTON PIN INSPECTION
1. Measure:
9
Piston skirt diameter
P
a
= 10 mm (0.4 in) from the piston bot-
tom edge
Out of specification
→
Replace.
Cylinder taper = Maximum A – Minimum C.
Cylinder inside diameter:
48.600 – 48.620 mm
(1.9134 – 1.9142 in)
Cylinder inside diameter wear
limit:
48.620 mm (1.9142 in)
Cylinder taper limit:
0.05 mm (0.002 in)
Warpage limit:
0.05 mm (0.002 in)
Piston skirt diameter:
48.574 – 48.594 mm
(1.9123 – 1.9131 in)
Wear limit:
48.53 mm (1.911 in)
7DK40-03_b 6/12/09 5:50 PM Page 43
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