5 - 32
ENG
CYLINDER AND PISTON
2. Measure:
• piston-to-cylinder clearance
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a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
_
Measure cylinder bore “C” by taking side-to-
side and front-to-back measurements of the
cylinder. Then, find the average of the mea-
surements.
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a
5 mm (0.20 in) from the bottom edge of the pis-
ton
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
f. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
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Cylinder bore “C”
83.000 ~ 83.010 mm
(3.2677 ~ 3.2681 in)
Taper limit “T”
0.05 mm (0.002 in)
“C” = maximum of D
1
~ D
2
“T” = maximum of D
1
or D
2
– maximum of
D
5
or D
6
Piston size “P”
Standard
82.930 ~ 82.945 mm
(3.2650 ~ 3.2656 in)
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.060 ~ 0.075 mm
(0.0024 ~ 0.0030 in)
<Limit>: 0.15 mm (0.0059 in)
Summary of Contents for 2004 YP400
Page 1: ...2004 YP400 S 5RU1 AE1 SERVICE MANUAL ...
Page 2: ......
Page 8: ......
Page 9: ...GEN INFO 1 ...
Page 11: ...GEN INFO ...
Page 28: ...SPEC 2 ...
Page 30: ...SPEC ...
Page 77: ...CHK ADJ 3 ...
Page 137: ......
Page 138: ...CHAS 4 ...
Page 210: ......
Page 211: ...ENG 5 ...
Page 286: ...COOL 6 ...
Page 288: ...COOL ...
Page 299: ...FI 7 ...
Page 301: ...FI ...
Page 342: ...ELEC 8 ...
Page 378: ...8 34 ELEC LIGHTING SYSTEM ...
Page 404: ......
Page 405: ...TRBL SHTG 9 ...
Page 415: ......
Page 416: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...