Service Manual

SERVICE DATA
2-4
Piston
Outside diameter
(at piston skirt)
STD
ø 94
[3.70]
93.955 to 93.985
[3.6990 to 3.7002]
93.770
[3.6917]
0.25 [0.0098]/OS
94.205 to 94.235
[3.7089 to 3.7100]
94.020
[3.7016]
0.50 [0.0197]/OS
94.455 to 94.485
[3.7187 to 3.7199]
94.270
[3.7114]
Protrusion from crankcase
-0.25 to 0.15
[-0.0098 to 0.0059]
Bearing clearance check.
Weight difference in one engine
5 g
[0.2 oz.] or less
Piston ring
Clearance between
piston ring groove
No.1
compression ring
2.5 [0.098]
0.07 to 0.11
[0.0028 to 0.0043]
0.200
[0.0079]
Use the piston with replac-
ing
the piston rings until reach-
ing
the limits.
when reaching the limits,
replace the piston.
No.2
compression ring
2.0 [0.079]
0.045 to 0.085
[0.0018 to 0.0033]
0.150
[0.0059]
Oil ring 4.0 [0.157]
0.020 to 0.060
[0.0008 to 0.0024]
0.150
[0.0059]
Closed gap of ring
No.1
compression ring
0.30 to 0.50
[0.0118 to 0.0197]
1.50
[0.0591]
No.2
compression ring
0.50 to 0.70
[0.0197 to 0.0276]
1.50
[0.0591]
Oil ring
0.30 to 0.50
[0.0118 to 0.0197]
1.50
[0.0591]
Piston pin
Outside diameter
ø 30
[1.18]
29.994 to 30.000
[1.1809 to 1.1811]
Clearance between piston pin
0.000 to 0.016
[0.0000 to 0.0006]
0.050
[0.0020]
Clearance between connecting rod bushing
0.020 to 0.091
[0.0008 to 0.0036]
0.120
[0.0047]
Connecting
rod
Bushing inside diameter
ø 30
[1.18]
30.020 to 30.045
[1.1819 to 1.1829]
Bend and twist
0.05/100
[0.0020/3.94]
or less
0.15
[0.0059]
Clearance between crankpin and connect-
ing rod bearing (oil clearance)
0.030 to 0.090
[0.0012 to 0.0035]
0.200
[0.0079]
Use connecting rod with
replacing bearing until
reaching the limit.
when exceeding the limit,
re-gring the crankpin and
replace the bearing with
under size.
End play 33 [1.30]
0.15 to 0.35
[0.0059 to 0.0138]
0.50
[0.0197]
Replace connecting rod.
Weight difference of connecting rod assem-
bly in one engine
10 g
[0.35 oz.] or less
Flywheel
Flatness
0.15
[0.0059] or less
0.50
[0.0197]
Runout
0.15
[0.0059] or less
0.50
[0.0197]
Damper
Perpendicularity runout
0.5
[0.020] or less
1.5
[0.059]
Replace with a new one
after operating 8000 hours.
Periphery runout
0.5
[0.020] or less
1.5
[0.059]
Table 2-2 Maintenance service data table - Basic engine (2 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark