3-24
Measuring Cylinder Bore
1. Remove any burrs from the cylinder gasket surfaces.
2. See Figure 3-30. Install a head and base gasket, and
CYLINDER TORQUE PLATES (Part No. HD-33446A)
and TORQUE PLATE BOLTS (Part No. HD-33446-86).
Tighten the bolts using the same method used when
installing the cylinder head screws. See CYLINDER
HEAD, INSTALLATION on page 3-20.
NOTE
Torque plates, properly tightened and installed with gaskets,
simulate engine operating conditions. Measurements will vary
as much as 0.001 in. (0.025 mm) without torque plates.
3. Take cylinder bore measurement in ring path, starting
about 1/2 in. (13 mm) from top of cylinder, measuring
from front to rear and then side to side. Record readings.
4. Repeat measurement at center and then at bottom of
ring path. Record readings. This process will determine if
cylinder is out-of-round (or “egged”) and will also show
any cylinder taper or bulge.
5. See Table 3-6. If cylinder is not scuffed or scored and is
within service limit, see FITTING CYLINDER TO PIS-
TON on page 3-25.
NOTE
If piston clearance exceeds service limit, cylinders should be
rebored and/or honed to next standard oversize, and refitted
with the corresponding piston and rings. Do not fit piston
tighter than 0.0007 in. (0.018 mm) See SPECIFICATIONS.
Figure 3-29. Checking Gasket Surfaces
2781a
Gasket surface flat within
0.006 in. (0.15 mm)
Figure 3-30. Measuring Cylinder Bore Using Torque
Plates (Part No. HD-33446A)
Table 3-6. 1200cc Cylinder Bore
Service Wear Limits
BORE SIZES IN. MM
Standard Bore 3.5008 88.920
0.005 in. OS bore
(0.13 mm)
3.5050 89.027
0.010 in. OS bore
(0.25 mm)
3.5100 89.154
0.020 in. OS bore
(0.51 mm)
3.5200 89.408
0.030 in. OS bore
(0.76 mm)
3.5300 89.662
2782a
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