1D-51 Engine Mechanical:
Piston Ring Free End Gap and Piston Ring End Gap
Measure the piston ring free end gap using the 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): 09900–20101 (Vernier calipers (1/15 mm,
150 mm))
Piston ring free end gap
Service limit: (1st): 7.0 mm (0.28 in)
Special tool
(B): 09900–20803 (Thickness gauge)
Piston ring end gap
Service limit: (1st): 0.50 mm (0.020 in)
Piston Pin and Pin Bore
Measure the piston pin bore inside diameter using the
small bore gauge. If the measurement is out of
specification, replace the piston.
Special tool
(A): 09900–20602 (Dial gauge (1/1000 mm, 1
mm))
(B): 09900–22403 (Small bore gauge (18 – 35
mm))
Piston pin bore
Service limit: 19.030 mm (0.7492 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: 18.980 mm (0.7472 in)
Engine Bottom Side Disassembly
BA02J21406032
NOTE
The crankcase must be separated to service
the crankshaft and conrod.
1) Remove the engine assembly from the frame. Refer
to “Engine Assembly Removal” (Page 1D-20).
2) Remove the engine top side. Refer to “Engine Top
Side Disassembly” (Page 1D-27).
Starter Motor
Remove the starter motor (1).
(A)
I649G1140265-03
(B)
IA02J1140046-01
(B)
(A)
IA02J1140047-01
(C)
I649G1140268-03
1
IA02J1140254-04
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