Piston, Ring, Pin, and Connecting Rod Removal and Installation: Removal

Crankshaft - Remove
Oil Jet - Remove

Metal or Hard Carbon - Remove

Courtesy of HONDA, U.S.A., INC.

1. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the piston as it is pushed out.

Piston/Connecting Rod Assembly - Remove

Courtesy of HONDA, U.S.A., INC.

1. Use the wooden handle of a hammer (A) to drive out the piston/connecting rod assembly (B).
NOTE:

Take care not to damage the cylinder with the connecting rod.

2. Reinstall the connecting rod bearings and the connecting rod caps after removing each piston/connecting rod assembly.

Mark each piston/connecting rod assembly with its cylinder number to make sure they are reinstalled in the original order.
The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.

Piston Ring - Remove

Courtesy of HONDA, U.S.A., INC.

1. Using a ring expander (A), remove the old piston rings (B).

2. Clean all ring grooves thoroughly with a squared-off broken ring or a ring groove cleaner with a blade to fit the piston grooves. File down the blade, if necessary. The top ring and second ring grooves are 1.2 mm (0.047 in) wide, and the oil ring groove is 2.0 mm (0.079 in) wide. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tool.

NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.

Piston Ring End Gap - Inspect

Courtesy of HONDA, U.S.A., INC.

1. Using a piston, push a new ring (A) into the cylinder bore 15-20 mm (0.59-0.79 in) from the bottom.

2. Measure the piston ring end-gap (B) with a feeler gauge:

If the gap is too small, check to see if you have the proper rings for your engine.
If the gap is too large, recheck the cylinder bore diameter against the wear limits . If the bore is beyond the service limit, the engine block must be rebored.

Piston Ring End-Gap

Top Ring
Standard (New):	0.200-0.350 mm (0.008- 0.013 in)
Service Limit:	0.6 mm (0.024 in)
Second Ring
Standard (New):	0.400-0.550 mm (0.016- 0.021 in)
Service Limit:	0.7 mm (0.028 in)
Oil Ring (TEIKOKU and UNITED)
Standard (New):	0.20-0.70 mm (0.008-0.027 in)
Service Limit:	0.8 mm (0.031 in)
Oil Ring (RIKEN and ALLIED)
Standard (New):	0.20-0.50 mm (0.008-0.019 in)
Service Limit:	0.55 mm (0.021 in)

Piston Pin - Remove

Courtesy of HONDA, U.S.A., INC.

1. Apply new engine oil to the piston pin snap rings (A), and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B).NOTE: Take care not to damage the ring grooves.

Courtesy of HONDA, U.S.A., INC.

2. Remove the snap rings (A) from both sides of each piston. Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection.