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Fitting Pistons

  1. Check cylinder bore for damage, wear and taper. See CYLINDER BLOCK ASSEMBLY . Determine if block must be rebored. See CYLINDER BLOCK  table under ENGINE SPECIFICATIONS. Rebore if necessary.
  2. Check outside diameter of piston. Measure at a point 1.04" (26.5 mm) from piston skirt end, in direction perpendicular to piston pin. Standard pistons are available in 2 sizes. Piston diameter is determined by numerical mark ("1" or "2") stamped on piston crown. See Fig 1. Number represents outer diameter of piston. See PISTON & CYLINDER DIAMETERS  table.
  3. Cylinder bore diameter is determined by a number on cylinder block head surface. See Fig 1. Stamped numbers on block should correspond to stamped numbers on piston crown. See PISTON & CYLINDER DIAMETERS  table.
    Fig 1: Locating Stamped Numbers On Cylinder Block & Pistons
    G00010556Courtesy of SUZUKI OF AMERICA CORP.
    PISTON & CYLINDER DIAMETERS

    Piston Number At Top Piston Outer Diameter - In. (mm) Cylinder Block Number Piston Bore Diameter - In. (mm)
    1 3.3063-3.3066 (83.980-83.988) 1 3.3075-3.3078 (84.011-84.018)
    2 3.3059-3.3062 (83.970-83.977) 2 3.3071-3.3074 (84.000-84.008
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