Installing The Cylinder - Yamaha 2008 YZ250F Fahrer- Und Wartungshandbuch

3. Measure:
• Ring end gap
→
Out of specification
You cannot measure the end gap on
the expander spacer of the oil control
ring. If the oil control ring rails show
excessive gap, replace all three rings.
End gap:
Standard
Top 0.15–0.25 mm
ring (0.006–0.010 in)
2nd 0.30–0.45 mm
ring (0.012–0.018 in)
Oil 0.10–0.40 mm
ring (0.004–0.016 in)
CHECKING THE PISTON PIN
1. Inspect:
• Piston pin
Blue discoloration/grooves
place, then inspect the lubrication
system.
2. Measure:
• Piston pin-to-piston clearance
Measurement steps:
a. Measure the outside diameter
(piston pin) "a".
If out of specification, replace the
piston pin.
Outside diameter (piston
pin):
15.991–16.000 mm
(0.6296–0.6299 in)
b. Measure the inside diameter (pis-
ton) "b".
Inside diameter (piston):
16.002–16.013 mm
(0.6300–0.6304 in)
Replace.
c. Calculate the piston pin-to-piston
clearance with the following for-
mula.
<Lim-
Piston pin-to-piston clearance =
it>
Inside diameter (piston) "b" -
0.50
Outside diameter (piston pin)
mm
"a"
(0.020
d. If out of specification, replace the
in)
piston.
0.80
Piston pin-to-piston
mm
clearance:
(0.031
in)
—
INSTALLING THE PISTON RING
→
Re-
AND PISTON
1. Install:
• Piston ring
Onto the piston.
• Be sure to install the piston rings so
that the manufacturer's marks or
numbers are located on the upper
side of the rings.
• Lubricate the piston and piston
rings liberally with engine oil.
2. Position:
• Top ring
• 2nd ring
• Oil ring
Offset the piston ring end gaps as
shown.
a. Top ring end
b. 2nd ring end
CYLINDER AND PISTON
0.002–0.022 mm
(0.0001–0.0009 in)
<Limit>:0.07 mm (0.003
in)
4-27
c. Oil ring end (upper)
d. Oil ring
e. Oil ring end (lower)
3. Install:
• Piston "1"
• Piston pin "2"
• Piston pin clip "3"
• Apply engine oil onto the piston pin
and piston.
• Be sure that the arrow mark "a" on
the piston points to the exhaust side
of the engine.
• Before installing the piston pin clip,
cover the crankcase with a clean
rag to prevent the piston pin clip
from falling into the crankcase.
• Install the piston pin clips with their
ends facing downward.

INSTALLING THE CYLINDER

1. Lubricate:
• Piston
• Piston ring
• Cylinder
Apply a liberal coating of engine oil.
2. Install:
• Dowel pin "1"
• O-ring "2"
Apply the lithium soap base grease
on the O-ring.
3. Install:
• Cylinder gasket "1"
• Cylinder "2"
New