Fitting Pistons
- Inspect block for distortion of deck surface. Warpage limit is .0024" (.06 mm). Inspect block for cracks, scratches or other defects. Measure bores at 3 levels for taper, out-of-round and wear.
- If bore wear exceeds .0015" (.04 mm), or taper and out-of-round exceed .0039" (.10 mm) from standard bore size, block must be rebored and oversize pistons installed. Pistons are available in .010" (.25 mm) and .020" (.50 mm) oversizes.
- Check outside diameter of piston by measuring at a point .590" (15.0 mm) from bottom of skirt and at 90 degrees to pin bore. Standard pistons are available in 2 sizes in order to ensure correct piston-to-cylinder clearance. Each standard piston has a number "1" or number "2" stamped on piston crown.
- The cylinder block is stamped with 4 numbers, either number "1" or number "2". The first number stamped on cylinder block indicates bore size of No. 1 cylinder. Second number indicates bore size of No. 2 cylinder. Third number indicates bore size of No. 3 cylinder. Fourth number indicates bore size of No. 4 cylinder.
- Install piston stamped number "1" into cylinder stamped number "1". Use a piston stamped number "2" in a cylinder stamped number "2". See Fig 1
.
Courtesy of SUZUKI OF AMERICA CORP.