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ENGINE 3-37

CYLINDER BORE

Measure the cylinder bore diameter at six places. If any one of the

measurements exceeds the limit, overhaul the cylinder and re-

place the piston with an oversize piston. The remaining cylinders

must be also rebored accordingly. Otherwise, the imbalance might

cause excess vibration.

! Cylinder bore

Service Limit: 79.080 mm

" 09900-20508: Cylinder gauge set

PISTON DIAMETER

Using a micrometer, measure the piston’s outside diameter at the

place shown in Fig. If the measurement is less than the limit, re-

place the piston.

! Piston diam.

Service Limit: 78.880 mm

" 09900-20204: Micrometer (75 – 100 mm)

PISTON-CYLINDER CLEARANCE

As a result of the above measurement, if the piston clearance

exceeds the following limit, overhaul the cylinder and use an over-

size piston, or replace both cylinder and piston.

! Piston to cylinder clearance

Service Limit: 0.12 mm

Piston oversize: 0.5 mm

PISTON RING-GROOVE CLEARANCE

Using a thickness gauge, measure the side clearances of the 1st

and 2nd rings. If any of the clearances exceeds the limit, replace

both piston and piston rings.

" 09900-20803: Thickness gauge

! Piston ring-groove clearance

Service Limit

1st : 0.18 mm

2nd: 0.15 mm

15 mm

Suzuki GSX1200 1999 User Manual

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