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Old 06-20-2011, 03:28 PM   #1 (permalink)
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Piston to cylinder wall clearance 2004 500SS

I cant seem to download the service manual so I thought I would post this simple question.
The machine shop thats boring the jugs on my 2004 MXZ 500SS would like to know the piston to cylinder wall clearance spec before they start the work.
Can anyone tell me?
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Old 06-21-2011, 06:23 AM   #2 (permalink)
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Not sure, but they should have the piston kits there at the shop before they start any work!
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Old 06-21-2011, 07:02 AM   #3 (permalink)
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Quote:
Originally Posted by smallengineguy View Post
Not sure, but they should have the piston kits there at the shop before they start any work!
Yeah, they do have the pistons but the machinist asked me to get these specs too.
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Old 06-21-2011, 07:04 AM   #4 (permalink)
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Not sure exactly, but should not exceed .003.
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Old 06-21-2011, 05:17 PM   #5 (permalink)
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^^ that answer is much too generic to try to go by. Cylinder to wall clearances vary greatly depending on if its a cast piston, forged, factory bore + compression, etc.


For an example, my 98 XC600 with forged Wisecos was .0065" if I remember right as they are forged, have a greater expansion rate than cast, and will tighten that clearance up when they warm. Cast dont expand nearly as much and will require tighter tolerances.

To the original poster I will do a quick search and see if I can dig anything up!
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Old 06-21-2011, 05:23 PM   #6 (permalink)
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500ss knocking after top end re-build - DOOTalk Forums

this guy ran oversized SPIs, but the piston to wall clearance should be the same regardless if they are a cast piston. It may vary by piston brand, and you will definately want to verify that before having any machining done. But according to him, SPIs run .005"-.006"... I would get a very definitive answer on this before you slap it together!
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Old 06-21-2011, 07:23 PM   #7 (permalink)
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Quote:
Originally Posted by 69CRUZR View Post
500ss knocking after top end re-build - DOOTalk Forums

this guy ran oversized SPIs, but the piston to wall clearance should be the same regardless if they are a cast piston. It may vary by piston brand, and you will definately want to verify that before having any machining done. But according to him, SPIs run .005"-.006"... I would get a very definitive answer on this before you slap it together!
Thats the plan... It's cost me over $800 in parts alone for this rebuild so I plan on doing it right.
Im going to try downloading the manual again, I had it on my computer all winter but then I had a virus and lost everything.
Thanks for the input.
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Old 06-21-2011, 07:47 PM   #8 (permalink)
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Well I tried again and still cant get the manual to download... When I choose the manual that I want it takes me to a RapidShare site, I click on free download and it leads me off into never never land. If anyone has any tips on how RapidShare works I'd be interested in hearing from you.
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Old 06-22-2011, 09:29 PM   #9 (permalink)
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Did you try right click and save as?
You may also need an ftp client.
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Old 06-23-2011, 06:43 AM   #10 (permalink)
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Well, I finally succeeded... I was able to find another free download that didn't require RapidShare. Soon as I have the pistons I'm off to the machine shop to get the jugs bored. I should have all the new parts by Monday and Im looking forward to having the sled back together. For some reason it really bothers me to see something in pieces in my garage.
Thanks to all for the help, if I have any questions during reassembly Ill be sure to post.
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