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6
. CYLINDER HEAD/CYLINDER/PISTON
6-0
6
 __________________________________________________________________________________  __________________________________________________________________________________  __________________________________________________________________________________  __________________________________________________________________________________  __________________________________________________________________________________ 
CYLINDER HEAD/CYLINDER/PISTON
 __________________________________________________________________________________ 
SERVICE INFORMATION........................................................6-2TROUBLESHOOTING..............................................................6-2CYLINDER HEAD....................................................................6-3CYLINDER/PISTON.................................................................6-6
6
 
6
. CYLINDER HEAD/CYLINDER/PISTON
6-1
Torque: 1.5
_
1.7kg-mTorque: 0.8
_
1.2kg-mTorque: 1.1
_
1.7kg-m(cold)
 
6
. CYLINDER HEAD/CYLINDER/PISTON
6-2
SERVICE INFORMATION
GENERAL INSTRUCTIONS
•
The cylinder head, cylinder and piston can be serviced with the engine installed in the frame.
•
Before disassembly, clean the engine to prevent dust from entering the engine.
•
Remove all gasket material from the mating surfaces.
•
Do not use a driver to pry between the cylinder and cylinder head, cylinder and crankcase.
•
Do not damage the cylinder inside and the piston surface.
•
After disassembly, clean the removed parts before inspection. When assembling, apply thespecified engine oil to movable parts.
SPECIFICATIONS
Standard (mm)Service Limit (mm)Item
BA10AB.AC.50BA10AB.AC 50
Cylinder head warpage
æ 
0.10
Piston O.D.(5mm from bottom of piston
38.970
_
38.95538.90
Cylinder-to- piston clearance
0.10
Piston pin hole I.D.
12.002
_
12.00812.03
Piston pin O.D.
11.994
_
12.011.98
Piston-to-piston pin clearance
¨ ¨
Piston ring end gap (top/second)
0.10
_
0.250.40
Connecting rod small end I.D.
17.005
_
17.01717.03
Cylinder bore
39.0
_
39.02539.05
TORQUE VALUES
Cylinder head bolt1.5
_
1.7kg-mExhaust muffler joint lock nut1.0
_
1.4kg-mExhaust muffler lock bolt3.0
_
3.6kg-mSpark plug1.1
_
1.7kg-m
●
TROUBLESHOOTING
Compression too low, hard startingor poor performance at low speedAbnormal noisy piston
•
Leaking cylinder head gasket
•
Worn cylinder and piston
•
Loose spark plug
•
Worn piston pin or piston pin hole
•
Worn, stuck or broken piston and piston rings
•
Worn connecting rod small end bearing
•
Worn or damaged cylinder and piston
Compression too high, overheatingor knockingAbnormal noisy piston rings
•
Excessive carbon build-up in cylinder head
•
Worn, stuck or broken piston ringsor on piston head
•
Worn or damaged cylinder 
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