3JE-03200-0 Tohatsu CARBURETOR ASSEMBLY

Illustration 1 g01455281
Top Piston Ring (1)
Install the top piston ring with the "UP-1" side toward the top of the piston. The top piston ring must be installed with the red colored stripe to the right of the ring end gap.Width of groove in new piston for the top piston ring ... 3.600 0.010 mm (0.1417 0.0004 inch)Thickness of new top piston ring ... 3.45 to 3.49 mm (0.136 to 0.137 inch)Clearance between the groove and the new top piston ring ... 0.130 to 0.190 mm (0.0051 to 0.0075 inch)Clearance between the ends of the piston ring in a cylinder liner bore of 170 mm (6.7 inch) ... 0.575 0.125 mm (0.0226 0.0049 inch)Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore ... 0.08 mm (0.003 inch)Intermediate Piston Ring (2)
Install the intermediate piston ring with the "UP-2" side toward the top of the piston. The intermediate piston ring must be installed with the green colored stripe to the right of the ring end gap.Width of groove in new piston for intermediate piston ring ... 3.600 0.010 mm (0.1417 0.0004 inch)Thickness of new intermediate piston ring ... 3.47 0.02 mm (0.137 0.001 inch)Clearance between the groove and the new intermediate piston ring ... 0.100 to 0.160 mm (0.0039 to 0.0063 inch)Clearance between the ends of the piston ring in a cylinder liner bore of 170 mm (6.7 inch) ... 0.80 0.20 mm (0.031 0.008 inch)Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore ... 0.08 mm (0.003 inch)Oil Control Piston Ring (3)
The ends of the oil control piston ring should be a distance of 180 degrees from the ring end gap when the oil control piston ring is assembled. The white colored portion of the piston ring must be visible at the ring end gap.Width of groove in new piston for the oil control piston ring ... 5.050 0.010 mm (0.1988 0.0004 inch)Thickness of new oil control piston ring ... 4.954 0.019 mm (0.1950 0.0007 inch)Clearance between the groove and the new oil control piston ring ... 0.067 to 0.125 mm (0.0026 to 0.0049 inch)Clearance between the ends of the piston ring in a cylinder liner bore of 170 mm (6.7 inch) ... 0.70 0.19 mm (0.028 0.007 inch)Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore ... 0.08 mm (0.003 inch)Note: After the piston rings have been installed, rotate the piston rings so that the end gaps are 120 degrees from each other.Piston Pin (4)
Note: Lubricate the piston pin with clean engine oil before assembly.Outside diameter ... 69.962 0.005 mm (2.7544 0.0002 inch)Length ... 137.60 0.13 mm (5.417 0.005 inch) (A) Piston pin bore (vertical) ... 70.38 0.10 mm (2.771 0.004 inch)Pin Retainer (5)
Note: Install the pin retainer with the gap toward the top of the piston.Thickness of new pin retainer ... 2.40 0.08 mm (0.094 0.003 inch)Width of groove in new piston for the pin retainer ... 2.75 0.15 mm (0.108 0.006 inch)