Piston, Ring, Pin, & Connecting Rod Removal & Installation: Installation
- 1. Piston Pin - Install
1. Install a piston pin snap ring (A) only on one side
2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil.
3. Heat the piston to about 158°F (70°C). 4. Assemble the piston (A) and the connecting rod (B) with the arrow (C) and the embossed mark (D) on the same side. Install the piston pin (E) 5. Install the remaining snap ring (F)
6. Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston.
- 2. Piston Ring - Install
1. Install the top ring and the second ring as shown. The top ring (A) has a 1R mark, and the second ring (B) has a 2R mark. The manufacturing marks (C) must face upward.
2. After installing a new set of rings, measure the ring-to-groove clearances. Top Ring Clearance
Standard (New): 0.060-0.085 mm (0.003-0.003 in) Service Limit: 0.13 mm (0.005 in) Second Ring Clearance
Standard (New): 0.035-0.060 mm (0.002-0.002 in) Service Limit: 0.13 mm (0.005 in) 3. Rotate the rings in their grooves to make sure they do not bind.
4. Position the ring end gaps as shown. - 3. Piston/Connecting Rod Assembly - Install
1. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place
2. Apply new engine oil to the piston, the inside of the ring compressor, and the cylinder bore, then attach the ring compressor to the piston/connecting rod assembly
3. Position the mark (A) to face the cam chain side of the engine block.
4. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A). Push down on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore 5. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment before pushing the piston into place.
- 4. Crankshaft - Install