Checking and servicing the piston and rings (Suzuki DR-Z 250)

0

Piston diameter

Measure the piston diameter with a micrometer at 15 mm from the edge of the skirt.

If the piston diameter is less than the permissible value, replace the piston with a new one.

09900-20204: Micrometer (75–100 mm)
Piston diameter. Allowable limit: 72.880 mm

Piston ring clearances

Measure the side clearances on the first and second piston rings with a feeler gauge. If any clearance exceeds the permissible limit, replace the piston and piston rings.

The article is taken from the website [motoinstruction.ru]

09900-20803: Probe
09900-20205: Micrometer (0-25mm)

Piston ring clearance.
Permissible limit: first and second: 0.18 mm

Piston groove width. Standard:

• First and second: 1.01–1.03 mm
• Oil groove: 2.01-2.03 mm

Piston ring. Standard thickness:
First and second: 0.97–0.99 mm

Piston ring gap in free state and in assembly

Measure the gap in the piston ring lock in a free state with a caliper, then install the ring in the cylinder and measure the gap in the lock with a feeler gauge. If any gap exceeds the permissible limit, replace the piston ring with a new one

09900-20102: Vernier caliper

Lock gap in free state: Permissible limit: first - 6.1 mm, second - 6.2 mm

09900-20803: Probe

The gap in the piston ring lock installed in the cylinder.
Permissible limit for the first and second: 0.50 mm

Piston pin and hole for it

Measure the piston pin bore diameter with a bore gauge. If the diameter exceeds the permissible limit, replace the piston with a new one.

09900-20602: Dial indicator (1/1000 mm)
09900-22403: Bore gauge (18-35 mm)
Permissible limit of piston pin bore diameter: 19.030 mm

Measure the piston pin diameter in three places with a micrometer. If any of the dimensions exceed the permissible limit, replace the piston pin with a new one.

09900-20205: Micrometer (0-25mm)
Piston pin outer diameter
Allowable limit: 18.980 mm

See this article in russian language

Checking the piston rings Yamaha FZ1 Fazer (2006-2015)
Piston rings — inspection and installation Honda Africa Twin 750 (1989-2003)
Checking the piston Aprilia SL 750 Shiver (2007-2016)
Overhaul piston rings Ducati ST2 (1997-2003)
Removing and checking piston БМВ F 650 GS (2000-2007)

Article about repair motorcycles «Suzuki DR-Z DRZ-250» (1996-2007): «Checking and servicing the piston and rings»: https://motoinstruction.ru/en/Suzuki/DR-Z/250/engine/repair/111080 <a href="https://motoinstruction.ru/en/Suzuki/DR-Z/250/engine/repair/111080">Checking and servicing the piston and rings</a> - article about repair motorcycles «Suzuki DR-Z DRZ-250» (1996-2007) from section «Engine repair». [url=https://motoinstruction.ru/en/Suzuki/DR-Z/250/engine/repair/111080]Checking and servicing the piston and rings[/url] - article about repair motorcycles «Suzuki DR-Z DRZ-250» (1996-2007) from section «Engine repair».