8.

CYLINDER/PISTON

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CYLINDER/PISTON

System Diagram 8-0 Piston/Piston Ring Removal 8-5

Service Information 8-1 Piston Ring Installation 8-8
Troubleshooting 8-2 Piston Installation 8-9
Cylinder / Piston 8-3 Cylinder Installation 8-10
Cam Chain Tensioner Lifter 8-11

SERVICE INFORMATION
GENERAL
• The engine must be removed from the frame to service the cylinder and piston.
Be careful not to damage the mating surfaces by using a screwdriver when removing the cylinder. Do not strike the
cylinder too hard during removal, even with a rubber or plastic mallet, to prevent the possibility of damage to the
When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original
Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
When installing piston pin, apply molybdenum disulfide oil to the whole surface of piston pin.
Take care not to damage the cylinder wall and piston.

SERVICE DATA Unit: mm

Item Standard Service Limit

Cylinder I.D. 65.500 65.510 65.60
Out of round - 0.10
Taper - 0.10
Warpage - 0.10

Piston, Piston O.D 65.470 65.490 65.42

piston ring Piston pin hole I.D. 15.002 15.008 15.04
and piston Piston pin O.D. 14.994 15.000 14.96
pin Piston-to-piston pin clearance 0.002 0.014 0.07
Connecting rod small end I.D. 15.010 15.028 15.042
Cylinder-to-piston clearance 0.010 0.040 0.15
Connecting rod-to-piston pin clearance 0.010 0.034 0.10
Piston ring-to-groove Top 0.005 0.020 0.10
Clearance Second 0.005 0.020 0.10
Piston ring end gap Top 0.20 0.35 0.70
Second 0.35 0.50 0.9
Oil (side rail) 0.20 0.70 1.00

Piston slide base 070 HH 198 027

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 CYLINDER/PISTON

TROUBLESHOOTING
Compression too low, hard to start or poor performance at low speed
Leaking cylinder head gasket
Loose spark plug
Worn, stuck or broken piston rings
worn or damaged cylinder or piston

Compression too high, overheating or knocking

Excessive carbon build-up in cylinder head or on top of piston

Excessive smoke
Worn cylinder or piston rings
Improper installation of piston rings
Scored or scratched piston or cylinder wall

Excessive noise
Worn cylinder and piston 8
worn piston pin and piston pin hole

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CYLINDER/PISTON
CAM CHAIN GUIDE
CYLINDER /PISTON
CYLINDER REMOVAL
Remove the cylinder head (page 7-4).
Remove the cam chain guide.

CYLINDER

Lift the cylinder and remove it, being careful not to

damage the piston with the stud bolts.
Clean the top of the cylinder throughly.

NOTE :
Be careful not to damage the mating surfaces by
using a screwdriver when disassembling the cylinder.

Remove the dowel pins.

Remove the gasket.

DOWEL PINS GASKET

STUD
205.4 +1
213.4 +1

STUD REPLACEMENT
Remove the studs from the crankcase.
Install the new studs into the crankcase embed to
incomplete threads. Embed to Embed to
incomplete incomplete
thread thread

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 CYLINDER/PISTON

CYLINDER INSPECTION
Inspect the cylinder wall and area near TDC (Top Dead
Center) carefully for scoring and wear.

Wear

BORE DIAL GAUGE

Measure and record the cylinder I. D. at three levels in

both the X and Y axis. Take the maximum reading to
determine the cylinder wear.
SERVICE LIMIT: 65.60 mm 8
Calculate the cylinder-to-piston clearance (page 8-1).

CYLINDER

IN EX
Calculate the cylinder for taper and ovality at three levels
in an X and Y axis. Take the maximum reading to TOP
determine the out of round.
SERVICE LIMIT: MIDDLE
Taper : 0.10 mm
Ovality : 0.10 mm BOTTOM
The cylinder must be rebored and an oversize piston
fitted if the service limit is exceeded.
The following oversize pistons are available:
0.25 mm - 1.00 mm
The cylinder must be rebored so that the clearance for
and oversize piston is 0.010 - 0.040 mm .

Check the cylinder for warpage by placing a straight

edge and a feeler gauge across the studs and bolt holes

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CYLINDER/PISTON
NOSE PLIER
PISTON /PISTON RING REMOVAL
Remove the piston pin clip using nose pliers.
NOTE :
Place a clean shop towel over the crankcase to prevent

CAUTION
Do not damage or scratch the piston
Do not apply side force to the connecting rod.

PISTON PIN CLIP

PISTON

Press the piston pin out of the piston using a soft shaft
and remove the piston.

PISTON PIN

Inspect the piston rings for movement by pressing the

rings. The rings should be able to move in its groove

NOTE :
Clean carbon deposits from the piston.
Clean carbon deposits from the piston ring grooves
with a ring that will be discarded. Never use a wire

PISTON
PISTON
Spread each piston ring and remove it by lifting it up at a

CAUTION
Do not damage the piston ring by spreading the
ends too far.
Be careful not to damage the piston during piston
ring removal.

PISTON RING

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 CYLINDER/PISTON
PISTON
PISTON /PISTON RING INSPECTION PISTON RING
Inspect the piston surface for scratches, wear, cracks or
other damage.
Inspect the ring grooves for excessive wear and carbon
build-up.

ABNORMAL WEAR

PISTON RING
PISTON MICROMETER

Measure each piston O. D. at 7 mm from the bottom,

and 900 to the piston pin hole.
SERVICE LIMIT: 65.42 mm
8
Calculate the cylinder-to-piston clearance. Take the
maximum reading to determine the clearance (Cylinder
7 mm
I. D. :page 8-4)
SERVICE LIMIT: 0.10 mm

PISTON

X
Measure each piston pin hole I. D. in an X and Y axis. Y

Take the maximum reading to determine I. D.

SERVICE LIMIT: 15.04 mm

I.D.

PISTON PIN MICROMETER

Measure the piston pin O. D. at three points.

SERVICE LIMIT: 14.96 mm
Calculate the piston-to-piston pin clearance.
SERVICE LIMIT: 0.07 mm

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CYLINDER/PISTON
CONNECTING ROD
Measure the connecting rod small end I. D.
SERVICE LIMIT: 15.042 mm
Calculate the connecting rod small end -to-piston pin
clearance.
SERVICE LIMIT: 0.10 mm

PISTON RING

Using a piston, push the piston ring securely into the

cylinder and measure the end gap using a feeler
gauge.
SERVICE LIMIT:
Top: 0.70 mm
Second: 0.90 mm
Oil: 1.00 mm

PISTON RING

Inspect the piston rings, and replace them if they are

worn.
NOTE :
Always replace the piston rings as a set
Reinstall the piston rings (page 8-8 ) into the piston
grooves.
Push in until outer surface of the piston ring is nearby FEELER GAUGE
flushed with the piston and measure the clearance using
a feeler gauge.
SERVICE LIMIT:
Top: 0.10 mm
Second: 0.10 mm

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 CYLINDER/PISTON
PISTON
PISTON RING INSTALLATION
Clean the piston heads, ring lands and skirts.
Carefully install the piston rings onto the piston with
their marking facing up.
CAUTION
Do not damage the piston ring by spreading the
far.
Be careful not to damage the piston during piston
installation.

NOTE :
Do not confuse the top and second rings. PISTON RING
After installing the rings they should rotate freely,

Space the ring end gaps 120 degrees apart.

MARK
8
2 TOP
TOP 1

120°
0
TOP RING 120
120° 120°
SECOND RING
0
120
SIDE RAIL
0
SPACER 120
0

SIDE RAIL 45

0
45

TOP RING
IN

SECOND RING
OIL RING

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CYLINDER/PISTON

PISTON INSTALLATION
Clean any gasket material from the cylinder mating
surface of the crankcase.

NOTE :
When cleaning the cylinder mating surface, place a
shop towel over the crankcase opening to prevent dirt

MATING SURFACE
PISTON
Apply molybdenum oil solution to the piston pin outer

Install the piston with its IN mark facing the intake side.
Install the piston pin.

PISTON PIN

Install new piston pin clips.

CAUTION
Always use new piston pin clips . Reinstalling used

PISTON PIN CLIP

END GAP
NOTE :
Place a shop towel over the crankcase opening to
prevent piston pin clips from falling into the
Set the piston pin clip in the groove properly.
Do not align the clip s end gap with the piston cut-

CUT OUT

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 CYLINDER/PISTON

CYLINDER INSTALLATION
Install the dowel pins and new gasket.
NOTE :
While cleaning the cylinder mating surface, place a
shop towel over the crankcase opening to prevent

Do not reuse the gasket, replace with new one.

DOWEL PINS GASKET

CYLINDER
CAUTION
Be careful not to damage the piston rings and
cylinder wall.
Be careful not to jam the piston rings to the cutaway
of the cylinder sleeve.
Apply clean engine oil to the cylinder wall, piston outer
8
surface and piston rings.
Place piston slide base under the piston.
Route the cam chain through the Cylinder and install the
cylinder over the piston compressing the piston rings
with your fingers.
PISTON / PISTON RING PISTON SLIDE BASE

CAM CHAIN GUIDE CAM CHAIN GUIDE

PISTON SLIDE BASE
PART NO: 070 HH 198 027
Insert the cam chain guide into the cylinder and
crankcase groove.
Install the cylinder head (page 7-20)

GROOVE

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CYLINDER/PISTON
PAN SCREW
CAM CHAIN TENSIONER LIFTER
REMOVAL
Remove the tensioner pan screw and o-ring.

O-RING CAMCHAIN TENSIONER LIFTER

CAM CHAIN TENSIONER

Turn the tensioner shaft clockwise with the stopper tool

to retract the tensioner, then insert the stopper fully to
hold the tensioner in the fully retracted position.

STOPPER TOOL

Remove the two mounting bolts.

MOUNTING BOLTS
CAM CHAIN TENSIONER LIFTER

Remove the cam chain tensioner lifter and gasket.

GASKET

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 CYLINDER/PISTON

INSPECTION
Check the lifter operation:
- The tensioner shaft should not go into the body
when it is
pushed.
- When it is turned clockwise with a stopper tool
(page 7-4), the tensioner lifter shaft should be pulled
into the body .
The shaft spring out of the body as soon as the
stopper tool is realeased.
CAMCHAIN TENSIONER LIFTER

INSTALLATION
Install a new gasket on the cam chain tensioner lifter.

GASKET
CAMCHAIN TENSIONER LIFTER

Install the cam chain tensioner lifter.

NOTE :
Never assemble the tensioner lifter to the engine with
the tension condition, as it may cause camchain noise /
wear.
MOUNTING BOLTS
Install the two mounting bolts and tighten them. PAN SCREW
Remove the stopper tool from the tensioner lifter.

Apply clean engine oil to a new o-ring and install it to the

lifter.
Install the tensioner lifter pan screw and tighten it.
O-RING

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MEMO