5-30
CYLINDER AND PISTON
3. Measure:
• Piston ring end gap
Out of specification
→
Replace the piston ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring end gap
Top ring
0.20-0.35 mm
(0.0079-0.0138 in)
<Limit>: 0.60 mm (0.0236 in)
2
nd
ring
0.35-0.50 mm
(0.0138-0.0197 in)
<Limit>: 0.85 mm (0.0335 in)
Oil ring
0.20-0.70 mm
(0.0079-0.0276 in)
EAS00265
CHECKING THE PISTON PIN
1. Check:
• Piston pin
Blue discoloration/grooves
→
Replace the
piston pin, and then check the lubrication
system.
2. Measure:
• Piston pin outside diameter “a”
Out of specification
→
Replace the piston
pin.
Piston pin outside diameter
22.991-23.000 mm
(0.9052-0.9055 in)
<Limit>: 22.971 mm (0.9044 in)
3. Measure:
• Piston pin bore inside diameter “b”
Out of specification
→
Replace the piston.
Piston pin bore inside diameter
23.004-23.015 mm
(0.9057-0.9061 in)
<Limit>: 23.045 mm (0.9073 in)
4. Calculate:
• Piston-pin-to-piston-pin-bore clearance
Out of specification
→
Replace the piston pin
and piston as a set.
Piston-pin-to-piston clearance
0.004-0.024 mm
(0.0002-0.0009 in)
<Limit>: 0.074 mm (0.0029 in)
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore inside diameter “b” –
Piston pin outside diameter “a”
INSTALLING THE PISTON AND
CYLINDER
• Oil ring expander “3”
• Lower oil ring rail “4”
• Upper oil ring rail “5”
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
a
Summary of Contents for MT-03
Page 7: ......
Page 9: ......
Page 25: ......
Page 53: ...2 28 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 8 9 5 10 11 A B C ...
Page 56: ...2 31 LUBRICATION CHART Pressure feed Splashed scavenge ...
Page 57: ...2 32 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS A A 1 3 2 2 4 A A A A ...
Page 59: ...2 34 LUBRICATION DIAGRAMS A A A A 3 1 2 3 4 ...
Page 60: ...2 35 LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Oil pump ...
Page 61: ...2 36 LUBRICATION DIAGRAMS 1 7 2 3 4 5 6 A ...
Page 63: ...2 38 LUBRICATION DIAGRAMS 1 6 5 4 3 2 ...
Page 65: ...2 40 CABLE ROUTING CABLE ROUTING ...
Page 67: ...2 42 CABLE ROUTING ...
Page 69: ...2 44 CABLE ROUTING ...
Page 71: ...2 46 CABLE ROUTING ...
Page 73: ...2 48 CABLE ROUTING ...
Page 75: ...2 50 CABLE ROUTING ...
Page 77: ...2 52 CABLE ROUTING ...
Page 79: ...2 54 CABLE ROUTING ...
Page 81: ...2 56 CABLE ROUTING ...
Page 83: ...2 58 CABLE ROUTING ...
Page 85: ...2 60 CABLE ROUTING ...
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Page 177: ...4 54 FRONT FORK WARNING Make sure the brake hoses are routed prop erly ...
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Page 273: ......
Page 287: ......
Page 325: ......
Page 339: ...8 12 CHARGING SYSTEM 2 A C magneto 5 Rectifier regulator 7 Battery 8 Main fuse ...
Page 341: ...8 14 CHARGING SYSTEM ...
Page 355: ...8 28 COOLING SYSTEM ...
Page 365: ...8 38 IMMOBILIZER SYSTEM ...
Page 366: ...8 39 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS ...
Page 368: ...8 41 ELECTRICAL COMPONENTS ...
Page 370: ...8 43 ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES ...
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Page 391: ......
Page 397: ...COLOR CODE ...
Page 398: ......
Page 399: ...YAMAHA MOTOR ITALIA S P A ...
Page 400: ...MT 03 2006 WIRING DIAGRAM ...