1997-2001 Honda TRX250 Fourtrax Recon Service Manual, Page 119Get this manual
CYLINDER HEADCYLINDERPISTON Remove the cylinder gasket and dowe pi ns
PISTON REMOVAL
Do not let the piston pin clips all into the crankcase
Remove the piston pin clip with liersPress the piston pin out of the piston and remove the pist on
CYLINDERPISTON INSPECTION
CYLINDER
Inspect the cy linder bore for wear or damageMeasure the cy linder 1.0in and axis at three levelsTake the maximum reading to determine the cylin der wear SERVICE LIMIT: 68 .6 mm (2.70 in) Calculate the piston -to-cyl inder clearanceTake maximum readi ng to determine the clearanceRefe to page 7-19 for measurement of the piston .0
SERVICE LIMIT: 68 .4 mm (2.69 in) Ca lcu late the taper and out of round at three levels in and ax isTake he maximum reading to determine them SERVICE LIMITSTaper0.10 mm (0.004 ill) Out of round: 010 mm (0.004 in) The cy linder must be rebo red and an oversize piston fitted if the service limi are exceeded The follow ing ove rsize pistons are available0.25 mm (0.0 10 in) 0.50 mm (0 .020 in) 0.75 mm (0.030 in) 1.00 mm (0039 in) The piston to cylinder clearance for the oversize piston must be: 0.0180.048 mm (0.00070.0019 in)TOP