MAINTENANCE AND ADJUSTMENT
Cylinder sleeve inspection
(I)
Using.
cylinder gauge, take LD. measurements in
tw
o di
rec
tions (parallel
an
d
tran
sv
erse
to
cr
ank
·
s
haft
axis.)
on e
ach
cylinder sleeve,
at
three
pl
aces
indicated belQw; and. from the s
ix
measurements
u!ken, det
enn
in
e (he amou
nt
s of w
ea
r
(in
com
pa
r·
sio
n with
Ut
e spe
cifi
ca
ti
ons
.
li
s
ted
bel
ow)
and
of
un
eve
n we
ar
to see
if
th
e
rep
a
ir
is
exceede
d;
jf so,
r
ebo
re the
sle
eve
to
the
ne
xt
ove
rs
iz.e
,
TBking 1.
0.
me-asurements.
on
cylinder sleeves
Crankcase
;31kcted
$urfl!r;8
I"
. ' ,'
. .
1 .
.:!
fT·
III
lee
L
2
EB
j
3
..
'.
Positi
ons
for checking Sl
oeV8
bo
re diameter
Unit: mm (in.l
Item Standard
Repair
Serv
ice
limit limit
94+
0
.
03
5
Cylinder
- 0
+0.20 I +1.20
sl
eeve
1.0
.
(3701~OO
l
~
(+0.008) i (+
0.047)
Out-of-round
O.DlS (0.0006),
max.
Taper
0.015
(0.
000
6),
max.
NOTE
: !
'TaperH
refer
s to
the
pllfRUelnes.s
of
bore
wa
ll.
48
(2)
Two ov.rsizes are provided for: +0.25
and
+0.5
nun
(0.0098
and 0.0197 in.).
Mte,
reharing, be
sure
to hone
the
bo
re to
the
specified
oversize
accur
ate
within
plu,
0.035 mtn (0.0014 in.)
Or
minus 0
mm
.
MadUning
the
bores
of
all four
sleeves
to
the same oversize is
pre
ferred. (pistons
and
piston
rings
are
availab
le
for
the
two
oversize:;;.)
(3)
If
any ,Ioeve
bore
is
unevenly worn, detennine tile
overSize, to which
th
e sleeves
are
to
be
reba
r
ed
.
on
t
he
basi,
of
th
e m:ll<imum wear noted. This
will
ensu
re
per
fect roundne
ss
in
the oversized
bo
r
es
.
[NOTE
)
If
the cylinder slee
ves
are found in good cond
i-
lion,
wi
th
the
wear far l
ess
than Ille repair limit,
it
is
permissible rebuild the engine with replace-
menl
piston rings. In s
uch
a case, be s
ur
e to
ream
off
t
he
"ridge" and,
as
necessa.ry. hone
the bore.
'-
,.
,
~
--~
..
I
LL.i
Removing
rid
ge
with
ri
dge
rea
mer
Cylinder sleeve
re
pJacem
eDt
A cylinder sleeve badly scuffed
or
WOrn
down beyond
the
service
lim
it must
be
replaced
by a new one
and
,
in
such a case. it is not necessary
to
replace the other
sleeves.
If,
nowe'ler.
the
cylinder hole becomes damaged in the
prCH:e.ss
of
removing
a sleeve, then
the
hole
must
be
re
bp
red
for
repair
and
,
only
in
s
uch
a
case,
all
th
e
fou
r
sl.eves must
be
replaced. The procedure
of
replacing t
he
cylinder sleeve is
as
follows:
(1)
Set
the boring machine
on
the crankcase, and
cent
er
it
on
the
!l
I
e-eve
by
referring
to
the
lower
part
of
the ,leeve wltJeh
is
I
...
t subject to uneven
we
ar
.
(2) Oporate the
machin.
to
cut
the sleeve until its
wall thickness dec
..
".,
to about 0.5 mm (0.0197
in
.)
(3) Taking care n
ot
to domage the cylinder hole,
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