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    NOTE: The Chrome (Silver) Ring Should Be: ! Caution

    Uploaded by

    Leon Jaime Velasquez Cardenas
    1. The document provides instructions for measuring piston skirt clearance in a cylinder, installing piston rings, cleaning and inspecting the cylinder head and cylinder, and measuring camshaft runout and lobe heights. 2. Key steps include measuring the cylinder and piston diameter to determine clearance, installing the rings with the proper orientation and staggered end gaps, and using wet-or-dry sandpaper to true the cylinder head and cylinder mating surfaces. 3. The document also outlines procedures for inspecting components like the camshaft, measuring camshaft runout, lobe heights, and camshaft to cylinder head clearance. Maintaining proper specifications is important for engine assembly and performance.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    NOTE: The Chrome (Silver) Ring Should Be: ! Caution

    Uploaded by

    Leon Jaime Velasquez Cardenas
    5 views4 pages
    1. The document provides instructions for measuring piston skirt clearance in a cylinder, installing piston rings, cleaning and inspecting the cylinder head and cylinder, and measuring camshaft runout and lobe heights. 2. Key steps include measuring the cylinder and piston diameter to determine clearance, installing the rings with the proper orientation and staggered end gaps, and using wet-or-dry sandpaper to true the cylinder head and cylinder mating surfaces. 3. The document also outlines procedures for inspecting components like the camshaft, measuring camshaft runout, lobe heights, and camshaft to cylinder head clearance. Maintaining proper specifications is important for engine assembly and performance.

    Original Title

    03-02-1

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    1. The document provides instructions for measuring piston skirt clearance in a cylinder, installing piston rings, cleaning and inspecting the cylinder head and cylinder, and measuring camshaft runout and lobe heights. 2. Key steps include measuring the cylinder and piston diameter to determine clearance, installing the rings with the proper orientation and staggered end gaps, and using wet-or-dry sandpaper to true the cylinder head and cylinder mating surfaces. 3. The document also outlines procedures for inspecting components like the camshaft, measuring camshaft runout, lobe heights, and camshaft to cylinder head clearance. Maintaining proper specifications is important for engine assembly and performance.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    5 views4 pages

    NOTE: The Chrome (Silver) Ring Should Be: ! Caution

    Uploaded by

    Leon Jaime Velasquez Cardenas
    1. The document provides instructions for measuring piston skirt clearance in a cylinder, installing piston rings, cleaning and inspecting the cylinder head and cylinder, and measuring camshaft runout and lobe heights. 2. Key steps include measuring the cylinder and piston diameter to determine clearance, installing the rings with the proper orientation and staggered end gaps, and using wet-or-dry sandpaper to true the cylinder head and cylinder mating surfaces. 3. The document also outlines procedures for inspecting components like the camshaft, measuring camshaft runout, lobe heights, and camshaft to cylinder head clearance. Maintaining proper specifications is important for engine assembly and performance.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    ATV-1069 ATV-1085B

    2. Install the compression rings (1 and 2) so the let-


    Measuring Piston Skirt/ ter(s) on the top surface of each ring faces the
    Cylinder Clearance dome of the piston. Rotate the rings until the ring
    end gaps are on directly opposite sides of the pis-
    1. Measure the cylinder front to back in six places. ton according to the illustration.
    „NOTE: The chrome (silver) ring should be
    installed in the top position.
    3

    CC397D
    2. Measure the corresponding piston diameter at a
    point 15 mm (0.6 in.) above the piston skirt at a
    right angle to the piston-pin bore. Subtract this MD1343A

    measurement from the measurement in step 1. The ! CAUTION


    difference (clearance) must be within specifica-
    tions. Incorrect installation of the piston rings will result in
    engine damage.
    Installing Piston Rings
    CYLINDER/CYLINDER HEAD
    1. Install ring expander (4) in the bottom groove of ASSEMBLY
    the piston; then install the thin oil rings (3) over
    the expander making sure the expander ends do „NOTE: If the cylinder/cylinder head assembly
    not overlap. Stagger the end gaps of the upper and
    lower thin oil rings according to the illustration. cannot be trued, they must be replaced.

    „NOTE: Note the direction of the exhaust side of Cleaning/Inspecting Cylinder Head
    the piston (5) for correct ring end gap orientation.
    ! CAUTION
    The cylinder head studs must be removed for this
    procedure.

    1. Using a non-metallic carbon removal tool, remove


    any carbon buildup from the combustion chamber
    being careful not to nick, scrape, or damage the
    combustion chamber or the sealing surface.
    2. Inspect the spark plug hole for any damaged
    threads. Repair damaged threads using a
    “heli-coil” insert.

    3-17
    3. Place the cylinder head on the surface plate cov- 2. Inspect the cylinder for pitting, scoring, scuffing,
    ered with #400 grit wet-or-dry sandpaper. Using warpage, and corrosion. If marks are found, repair
    light pressure, move the cylinder head in a figure the surface using a cylinder hone (see Honing Cyl-
    eight motion. Inspect the sealing surface for any inder in this sub-section).
    indication of high spots. A high spot can be noted
    by a bright metallic finish. Correct any high spots 3. Place the cylinder on the surface plate covered
    before assembly by continuing to move the cylin- with #400 grit wet-or-dry sandpaper. Using light
    der head in a figure eight motion until a uniform pressure, move the cylinder in a figure eight
    bright metallic finish is attained. motion. Inspect the sealing surface for any indica-
    tion of high spots. A high spot can be noted by a
    bright metallic finish. Correct any high spots
    ! CAUTION before assembly by continuing to move the cylin-
    Water or parts-cleaning solvent must be used in der in a figure eight motion until a uniform bright
    conjunction with the wet-or-dry sandpaper or dam- metallic finish is attained.
    age to the sealing surface may result.
    ! CAUTION
    Water or parts-cleaning solvent must be used in
    conjunction with the wet-or-dry sandpaper or dam-
    age to the sealing surface may result.

    CC996

    Measuring Cylinder Head


    Distortion
    CC997
    1. Remove any carbon buildup in the combustion
    chamber.
    Inspecting Cam Chain Guide
    2. Lay a straightedge across the cylinder head; then
    using a feeler gauge, check the distortion factor 1. Inspect cam chain guide for cuts, tears, breaks, or
    between the head and the straightedge. chips.
    3. Maximum distortion must not exceed specifications. 2. If the chain guide is damaged, it must be replaced.
    Honing Cylinder

    1. Using a slide gauge and a dial indicator or a snap


    gauge, measure the cylinder bore diameter in three
    locations from top to bottom and again from top to
    bottom at 90° from the first measurements for a
    total of six measurements. The trueness
    (out-of-roundness) is the difference between the
    highest and lowest reading. Maximum trueness
    (out-of-roundness) must not exceed specifications.

    CC141D

    Cleaning/Inspecting Cylinder

    1. Wash the cylinder in parts-cleaning solvent.

    3-18
    CC127D ATV-1068A
    2. Wash the cylinder in parts-cleaning solvent.
    Measuring Camshaft Runout
    3. Inspect the cylinder for pitting, scoring, scuffing,
    and corrosion. If marks are found, repair the sur- „NOTE: If the camshaft is out of tolerance, it must
    face using a ball hone. be replaced.
    „NOTE: To produce the proper 60° cross-hatch
    1. Place the camshaft on a set of V blocks; then posi-
    pattern, use a low RPM drill (600 RPM) at the rate tion the dial indicator contact point against the
    of 30 strokes per minute. If honing oil is not avail-
    able, use a lightweight petroleum-based oil. Thor-
    shaft and zero the indicator. 3
    oughly clean cylinder after honing using soap and
    hot water. Dry with compressed air; then immedi-
    ately apply oil to the cylinder bore. If the bore is
    severely damaged or gouged, replace the cylinder.

    CC283D
    2. Rotate the camshaft and note runout; maximum
    tolerance must not exceed specifications.
    Measuring Camshaft Lobe Height
    CC390D
    4. If any measurement exceeds the limit, bore the 1. Using a calipers, measure each cam lobe height.
    cylinder and install an oversized piston or replace
    the cylinder.
    „NOTE: Oversized piston and rings are available.
    The oversized piston and rings are marked for
    identification.

    ATV1013A
    2. The lobe heights must not exceed minimum speci-
    fications.

    3-19
    Inspecting Camshaft Bearing
    Journal

    1. Inspect the bearing journal for scoring, seizure


    marks, or pitting.
    2. If excessive scoring, seizure marks, or pitting is
    found, the cylinder head assembly must be
    replaced.
    Measuring Camshaft to
    Cylinder Head Clearance

    1. Remove the adjuster screws and jam nuts. CC145D


    6. If clearance is excessive, measure the journals of
    the camshaft.

    CC005D
    2. Place a strip of plasti-gauge in each of the cam-
    shaft lands in the cylinder head. CC287D

    3. Place the valve cover on the cylinder head and „NOTE: If the journals are worn, replace the cam-
    secure with the valve cover cap screws. Tighten shaft; then measure the clearance again. If it is still
    securely. out of tolerance, replace the cylinder head.
    „NOTE: Do not rotate the camshaft when measur- Inspecting Camshaft Spring/Drive
    ing clearance. Pin
    4. Remove the cap screws securing the valve cover to 1. Inspect the spring and unloader pin for damage.
    the cylinder; then remove the valve cover and
    camshaft.

    CF061A

    MD1261 „NOTE: With the weight extended, the unloader


    5. Match the width of the plasti-gauge with the chart pin should be flat-side out; with the weight
    found on the plasti-gauge packaging to determine retracted, the unloader pin should be round-side
    camshaft to cylinder head and valve cover clear- out.
    ance.

    3-20

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