Yanmar 1GM User Manual page 103

SINGLE-CYLINDER ENGINES
ing it out with an appropriate size drift or
pin punch. When removing a large core
plug, the use of a universal impact slide
hammer
is
recommended.
3. Clean the plug bore thoroughly to remove all traces of
the old sealer. Inspect the bore for any damage that might
interfere with proper sealing of the new plug.
97
4. Coat the inside diameter of the plug bore and the outer
diameter of the new plug with sealer. Use an oil-resistant
sealer if the plug is to be installed in an oil gallery or a wa-
ter-resistant sealer for plugs installed in the water jacket.
5. Install the new core plug with an appropriate size core
plug installation tool (Figure 92), driver or socket. The
outside edge ofthe plug should be 2-3 mm (0.08-0.12 in.)
inside the block.
6. Repeat Steps 1-5 to replace each remaining core plug.
Bore
Stroke
Displacement
Number of cylinders
Cylinder bore diameter
Bore out-of-round-max.
Cylinder block warpage-max.
Piston diameter
Standard
Wear limit
Piston top clearance
Piston ring side clearance
Top ring
Second ring
Oil ring
Ring end gap (all rings)
Piston pin diameter
Piston pin hole diameter
In piston
In rod
Piston pin clearance
In rod
In piston
Piston ring width
Top & second ring
Oil control ring .
Crankshaft main journal diameter
Timing gear end
Flywheel end
Journal out-of-round-max.
Crankshaft end play
Crankshaft runout-max.
Main bearing clearance
Timing gear end
Flywheel end
Crankshaft thrust bearlng-min.
Front
Inner
Crankpin diameter
Journal out-of-round-max.
Crankpin bearing clearance
Connecting rod side clearance
Cylinder head warpage-max.
Table 1 ENGINE SPECIFICATIONS (1GM, 1GM10)
75 mm (2.95 in.)
72 mm (2.83 in.)
318 cc (19.4 cu.
ln.)
1
75.000-75.030 mm (2.9528-2.9540 in.)
0.02 mm (0.0008 in.)
0.07 mm (0.0028
ln.)
74.910-74.940 mm (2.9492-2.9504
ln.)
74.850 mm max. (2.9468 ln.)
0.68-0.88 mm (0.027-0.035 in.)
0.065-0.100 mm (0.0026-0.0039 in.)
0.035-0.070 mm (0.0014-0.0028 in.)
0.020-0.055 mm (0.0008-0.0022 ln.)
0.20-0.40 mm (0.008-0.016 in.)
19.991-20.000 mm (0.7870-0.7874
ln.)
19.995-20.008 mm (0.7872-0.7877 ln.)
20.000 mm (0.7874 in.)
0.025-0.047 mm (0.0010-0.0019 in.)
0.005 mm tight-O.017 mm loose
(0.0002 in. tight-0.0007 in. loose)
1.97-1.99 mm (0.0776-0.0783 in.)
3.97-3.99 mm (0.1563-0.1571 ln.)
43.950-43.964 mm (1.7303-1.7309 in.)
59.950-59.964 mm (2.3602-2.3608 ln.)
0.01 mm (0.0004 In.)
0.06-0.19 mm (0.0024-0.0075 in.)
0.15 mm (0.006 in.)
0.036-0.092 mm (0.0014-0.0036 in.)
0.036-0.095 mm (0.0014-0.0037 in.)
2.75 mm (0.108 in.)
2.25 mm (0.089 in.)
39.950-39.964 mm (1.5728-1.5734 in.)
0.01 mm (0.0004 in.)
0.028-0.086 mm (0.0011-0.0034 in.)
0.2-0.4 mm (0.008-0.016 in.)
0.07 mm (0.003 in.)
(continued)