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When you are squeezing something between the piston and the head button your not getting all the way to top dead center. There is enough clearance between the crank pin and rod bushing plus the wrist pin and small end bushing to get that much difference.

If you have a newer tight piston and sleeve and roll it slow too TDC, measure then put some caster oil on the P\S and roll it fast and catch it just right on TDC so there is no resistance on the crank and rod, you will see .003 to .006 difference.

What I'm getting at is you need to make sure it really is at TDC. Then measure from top of piston to top of liner. Then measure how far the head button goes into the sleeve. The difference is your head clearence. A depth gage and a set of calipers are very helpfull.

There are more accurate ways of doing these measurements but this is I believe an acceptable way to do it without buying expensive tools.

Good luck.
 
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