2. Cylinder and Piston

2. CYLINDER AND PISTON





1) The cylinder bore size is stamped on the cylinder block's front upper surface.

NOTE: Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as a guide line in selecting a standard piston.

Standard diameter:
A: 99.505 - 99.515 mm (3.9175 - 3.9179 in)
B: 99.495 - 99.505 mm (3.9171 - 3.9175 in)





2) How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the Figure, using a cylinder bore gauge.

CAUTION: Measurement should be performed at a temperature 20°C (68°F).

Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)

3) When piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.





4) How to measure the outer diameter of each piston Measure the outer diameter of each piston at the height shown in the Figure. (Thrust direction)

CAUTION: Measurement should be performed at a temperature of 20°C (68°F).

Piston outer diameter:
Standard
A: 99.485 - 99.495 mm (3.9167 - 3.9171 in)
B: 99.475 - 99.485 mm (3.9163 - 3.9167 in)
0.25 mm (0.0098 in) oversize
99.725 - 99.735 mm (3.9262 - 3.9266 in)
0.50 mm (0.0197 in) oversize
99.975 - 99.985 mm (3.9360 - 3.9364 in)

5) Calculate the clearance between cylinder and piston.

CAUTION: Measurement should be performed at a temperature of 20°C (68°F).

Cylinder to piston clearance at 20°C (68°F):
Standard
0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit
0.050 mm (0.0020 in)

6) Boring and honing
(1) If the value of taper, out-of-roundness, or cylinder- to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston.

CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only.

(2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase.

CAUTION: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter.

Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)