ODES UTV Desertcross 1000cc-3 - CYLINDER INSPECTION

3. ENGINE
3-
58
Cylinder Inspection
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If so, replace
cylinder.
Cylinder Taper
Measure cylinder bore at3 recommended positions.
A. First measurement (from cylinder bottom)
B. Second measurement
C. Third measurement
CYLINDER TAPER MEASUREMENTS
ENGINE
MEASUREMENT
SPECIFICATION
800R
engine
A
5mm(.197in)
B
63mm(2.48in)
C
32 mm(1 26in)
1000
engine
A
5mm(.197 in)
B
58 mm(2.283 in)
C
52 mm(2.047 in)
CYLINDER TAPER SPECIFICATION
NEW (MAXIMUM)
0.038mm(.0015in)
SERVICE LIMIT
0.090 mm(.0035in)
Distance between measurements should not exceed
the service limit mentioned above. Otherwise,
replace cylinder and piston rings.
Cylinder Out of Round
Measure cylinder diameter in piston axis direction
from top of cylinder . Take another measurement
90° from first one and compare .
NOTE: Take the same measuring points like
described in CYLINDER TAPER above.
A. Perpendicular to crankshaft axis
B. Parallel to crankshaft axis
CYLINDER OUT 0F ROUND
NEW (MAXIMUM)
0.015mm(.0006in)
SERVICE LIMIT
0.020 mm(.0008 in)
Cylinder Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTICE Always replace cylinder base gasket
before installing the cylinder.
NOTE: Make sure piston rings are properly spaced,
refer to PISTION in this subsection.
Apply engine oil:
- In the bottom area of the cylinder bore
- On the piston rings
- On the compressor tool.
Compress piston rings.
REQUIED TOOL
PISTON RING
COMPRESSOR
First mount cylinder 2.
NOTE: The cylinder can not be pushed fully over
the piston unless the piston is located at TDC.
Then remove the CRANKSHAFT LOCKING
BOLIT (P/N529 035 617).
Crank the engine further and position piston1 at
TDC.
Mount cylinder 1.
Put timing chain through the chain pit then put the
cylinder in place.