SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (2 / 4) Unit: mm [in.] 2-4 Inspection point Nominal Standard Limit Remark Piston Outside diameter (at piston skirt) STD ø 94 [3.70] 93.955 to 93.985 [3.6990 to 3.7002] 93.770 [3.6917] 0.25 [0.0098]/OS 94.205 to 94.235 [3.7089 to 3.7100] 94.020 [3.7016] 0.50 [0.0197]/OS 94.455 to 94.485 [3.7187 to 3.7199] 94.270 [3.7114] Protrusion from crankcase -0.25 to 0.15 [-0.0098 to 0.0059] Bearing clearance check.
Weight difference in one engine 5 g [0.2 oz.] or less Piston ring Clearance between piston ring groove No.1 compression ring 2.5 [0.098] 0.07 to 0.11 [0.0028 to 0.0043] 0.200 [0.0079] Use the piston with replac- ing the piston rings until reach- ing the limits. when reaching the limits, replace the piston.
No.2 compression ring 2.0 [0.079] 0.045 to 0.085 [0.0018 to 0.0033] 0.150 [0.0059] Oil ring 4.0 [0.157] 0.020 to 0.060 [0.0008 to 0.0024] 0.150 [0.0059] Closed gap of ring No.1 compression ring 0.30 to 0.50 [0.0118 to 0.0197] 1.50 [0.0591] No.2 compression ring 0.50 to 0.70 [0.0197 to 0.0276] 1.50 [0.0591] Oil ring 0.30 to 0.50 [0.0118 to 0.0197] 1.50 [0.0591] Piston pin Outside diameter ø 30 [1.18] 29.994 to 30.000 [1.1809 to 1.1811] Clearance between piston pin 0.000 to 0.016 [0.0000 to 0.0006] 0.050 [0.0020] Clearance between connecting rod bushing 0.020 to 0.091 [0.0008 to 0.0036] 0.120 [0.0047] Connecting rod Bushing inside diameter ø 30 [1.18] 30.020 to 30.045 [1.1819 to 1.1829] Bend and twist 0.05/100 [0.0020/3.94] or less 0.15 [0.0059] Clearance between crankpin and connect- ing rod bearing (oil clearance) 0.030 to 0.090 [0.0012 to 0.0035] 0.200 [0.0079] Use connecting rod with replacing bearing until reaching the limit.
when exceeding the limit, re-gring the crankpin and replace the bearing with under size. End play 33 [1.30] 0.15 to 0.35 [0.0059 to 0.0138] 0.50 [0.0197] Replace connecting rod. Weight difference of connecting rod assem- bly in one engine 10 g [0.35 oz.] or less Flywheel Flatness 0.15 [0.0059] or less 0.50 [0.0197] Runout 0.15 [0.0059] or less 0.50 [0.0197] Damper Perpendicularity runout 0.5 [0.020] or less 1.5 [0.059] Replace with a new one after operating 8000 hours. Periphery runout 0.5 [0.020] or less 1.5 [0.059]