Refer to “piston ring removal and installation” .
Piston diameter
Measure the piston diameter using the micrometer at 15 mm (0.6 In) “a” from the skirt end. If the piston diameter is less than the service limit, replace the piston.
Special tool
(a): 09900–20203 (micrometer (50 –
75 mm))
Piston diameter service limit: 74.380 Mm (2.9283 In)
Piston-to-cylinder clearance
Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston.
Piston-to-cylinder clearance service limit: 0.120 Mm (0.0047 In)
Piston ring-to-groove clearance
Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. If any of the clearances exceed the limit, replace both the piston and piston rings.
Special tool
(a): 09900–20803 (thickness gauge)
(b): 09900–20205 (micrometer (0 – 25
mm))
Piston ring-to-groove clearance service limit (1st): 0.180 Mm (0.0071 In) service limit (2nd): 0.150 Mm (0.0059 In)
Piston ring groove width standard (1st): 0.83 – 0.85 Mm (0.0327 – 0.0335 In) standard (1st): 1.30 – 1.32 Mm (0.0512 – 0.0520 In) standard (2nd): 0.81 – 0.83 Mm (0.0319 – 0.0327 In) standard (oil): 1.51 – 1.53 Mm (0.0594 – 0.0602 In)
Piston ring thickness standard (1st): 0.76 – 0.81 Mm (0.0299 – 0.0319 In) standard (1st): 1.08 – 1.10 Mm (0.0425 – 0.0433 In) standard (2nd): 0.77 – 0.79 Mm (0.0303 – 0.0311 In)
Piston ring free end gap and piston ring end gap
Measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. If any of the measurements exceed the service limit, replace the piston ring with a new one.
Special tool
(a): 09900–20102 (vernier calipers
(200 mm))
Piston ring free end gap service limit (1st): 5.6 Mm (0.22 In) service limit (2nd): 6.4 Mm (0.25 In)
Special tool
(b): 09900–20803 (thickness gauge)
Piston ring end gap service limit (1st): 0.50 Mm (0.020 In) service limit (2nd): 0.50 Mm (0.020 In)
Piston pin and pin bore
Measure the piston pin bore inside diameter using the small bore gauge. If either is out of specification or the difference between these measurements surpass limits, replace the piston.
Special tool
(a): 09900–20602 (dial gauge)
(b): 09900–22401 (small bore gauge
(10 – 18
mm))
Piston pin bore service limit: 15.030 Mm (0.5917 In)
Measure the piston pin outside diameter at three positions using the micrometer. If any of the measurements are out of specification, replace the piston pin.
Special tool
(c): 09900–20205 (micrometer (0 – 25
mm))
Piston pin o.D.
Service limit: 14.980 Mm (0.5898 In)
Rear suspension inspection
Inspect rear suspension
every 12 000 km (7 500 miles, 24 months)
Inspect the rear shock absorber for oil leakage and
check that there is no play in the swingarm.
Replace any defective parts, if necessary. Refer to “rear shock absorber removal
and installation” in section 2c , “cushion lever ...
Fuel pump components
Fuel level gauge
Fuel pressure regulator assembly
O-ring
Joint
Fuel pump
Fuel pump case
Fuel mesh filter
10
N·m (1.0 Kgf-m, 7.0 Lbf-ft)
Apply engine oil.
Apply grease.
Do not reuse.
...
Rear wheel components
Rear axel nut
Collar
Dust seal
Bearing
Retainer
Rear sprocket
Sprocket mounting drum
Wheel damper
Bearing
Spacer
Air valve
Rear wheel
Wheel balancer
Rear tire
Dust seal
Collar
Rear brake disc
Rear axle
1 ...