Kohler KDW 1603 - Cylinders; Cylinder Roughness; Piston; Piston Availability

45
43
42
40 41
46
44
D(mm)
88,00÷88,01 88,100
A 88,00÷88,01 87,960÷87,967 0,033÷0,050
6
- 46 - - 46 -
Disassembly / Reassembly
Cylinders
Resetdialgaugewithacalibratedring.
CheckdiametersizeDat1,2and3;repeatthesameoperation
atthesameplacesafterturningthedialgaugeby90°.
CheckforwearintheXareawherepistonringsarelocated.
To check clearance with the matching piston measure the
diameter size at Z along theaxis whichruns atright anglesto
thedrivingshaft.
Limit value
(mm)
Cylinder roughness
 Important
Do not manually hone the cylinder bore surfaces with
emery cloth or other means.
The inclination of the cross-hatched marks left by machining
should range between 115°-140°; they should be uniform and
clearlyvisibleinbothdirections.
Averageroughnessshouldrangebetween0.5and1mm.
The cylinder surface which comes into contact with the piston
ringsshouldbemachinehonedwiththeplateausystem.
Piston
Removecirclipsandpistonpin.
Removepistonringsandcleangrooves.
Measure diameter Q at the A distance from the bottom of the
skirt(A=12mm)
In case of diameter wear exceeding 0.05 mm of the minimum
givenvaluereplacepistonandrings.
Nota:Theoversizesare0.50and1.00mm.TheTURBOpiston
differs from that of the NATURALLY ASPIRATED in its
coolingsprayerpassagenicheandaninsertintheslotof
therstring.
Piston availability
Thepistonsoversizedby0.5and1.0mmhavetheupratingreference
onthecrown,g.45-46.
Class
Ø Cylinder
(mm)
Ø Piston
(mm)
Clearance
(mm)
Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00