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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.
  2. Pistons are available in .0098" (.25 mm) and .0197" (.50 mm) oversize. 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.
  3. Cylinder bore diameter is determined by Red or Blue marks painted on cylinder block. See Fig 1.
  4. When installing piston into cylinder, ensure piston numerical mark matches cylinder painted mark. See PISTON & CYLINDER DIAMETERS  table. Ensure correct piston-to-cylinder clearance. See PISTONS & RINGS  table under ENGINE SPECIFICATIONS.
    Fig 1: Matching Pistons To Cylinder Block
    G00008474Courtesy of SUZUKI OF AMERICA CORP.
    PISTON & CYLINDER DIAMETERS

    Piston Number At Top Piston Outer Diameter - In. (mm) Cylinder Paint Color Piston Bore Diameter - In. (mm)
    1 3.3063-3.3066 (83.980-83.987) Red 3.3075-3.3078 (84.010-84.018)
    2 3.3059-3.3062 (83.969-83.977) Blue 3.3071-3.3074 (84.000-84.008)
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