Cylinder and Piston
CYLINDER AND PISTONCrankshaft and Piston:
1. The cylinder bore size is stamped on the cylinder block front upper surface.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines in selecting a standard piston.
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 as shown in the figure, using a cylinder bore gauge.
NOTE: Measurement should be performed at a temperature of 20°C (68°F).
3. When the 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 cylinder:
Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction)
NOTE: Measurement should be performed at a temperature of 20°C (68°F).
5. Calculate the clearance between cylinder and piston.
NOTE: Measurement should be performed at a temperature of 20°C (68°F).
Cylinder to piston clearance at 20°C (68°F):
Standard. -0.010 - 0.010 mm (-0.00039 - 0.00039 inch)
6. Boring and honing
1. If any of the measured value of taper, out-of-roundness or cylinder-to-piston clearance is not standard 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 cylinder block.
Limit of cylinder inner diameter: 100.005 mm (3.9372 inch)
NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention when measuring the cylinder diameter.