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Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE
1.
Cylinder Head and Valve Mechanism - Inspect and Repair................................. 6-3
1.1
Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure............................ 6-3
1.2
Rocker Bushing - Replace ........................................................................................................ 6-3
1.3
Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure ........................... 6-4
1.4
Valve Guide - Replace.............................................................................................................. 6-4
1.5
Valve Face - Inspect ................................................................................................................. 6-5
1.6
Valve Face - Reface ................................................................................................................. 6-5
1.7
Valve Seat - Reface.................................................................................................................. 6-6
1.8
Valve Seat - Replace ................................................................................................................ 6-6
1.9
Valve and Valve Seat - Lap ...................................................................................................... 6-8
1.10
Valve Bridge, Bridge Cap, Valve Cotter and Valve Rotator - Inspect ....................................... 6-8
1.11
Squareness and Free Length of Valve Spring - Measure......................................................... 6-9
1.12
Tappet - Inspect...................................................................................................................... 6-10
1.13
Pushrod Runout - Measure..................................................................................................... 6-10
1.14
Nozzle Gland Stud Bolt and Bridge Guide - Inspect and Replace.......................................... 6-10
1.15
Distortion of Cylinder Head Bottom Surface - Measure.......................................................... 6-11
2.
Rear Mechanism - Inspect and Repair................................................................. 6-12
2.1
Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure .......................... 6-12
2.2
Idler Bushing - Replace .......................................................................................................... 6-12
2.3
Cam Lift of Cam Shaft Lobe - Measure .................................................................................. 6-13
2.4
Camshaft Runout - Measure................................................................................................... 6-13
2.5
Camshaft Journal Outside Diameter - Measure ..................................................................... 6-13
2.6
Camshaft Bushing - Inspect.................................................................................................... 6-14
2.7
Camshaft Bushing - Replace .................................................................................................. 6-14
3.
Front Mechanism - Inspect and Repair................................................................ 6-16
3.1
Damper - Inspect Visually....................................................................................................... 6-16
3.2
Pulley - Inspect ....................................................................................................................... 6-16
4.
Piston and Connecting Rod - Inspect and Repair .............................................. 6-17
4.1
Piston - Inspect Visually.......................................................................................................... 6-17
4.2
Piston Weight ......................................................................................................................... 6-17
4.3
Piston Outside Diameter - Measure........................................................................................ 6-17
4.4
Piston Ring Groove - Inspect.................................................................................................. 6-18
4.5
Piston Pin Bore Inside Diameter - Measure............................................................................ 6-18
4.6
Piston Ring - Inspect Visually ................................................................................................. 6-18
4.7
Piston Ring End Gap - Measure ............................................................................................. 6-18
4.8
Piston Pin Outside Diameter - Measure ................................................................................. 6-19
4.9
Connecting Rod Bushing Inside Diameter - Measure............................................................. 6-19
4.10
Connecting Rod Bushing - Replace........................................................................................ 6-20
4.11
Connecting Rod Assembly Weight Rank................................................................................ 6-22
4.12
Bore Diameter and Roundness of Connecting Rod Big End - Measure................................. 6-22
4.13
Side Face Width of Connecting Rod Big End - Measure........................................................ 6-23
4.14
Connecting Rod Big End Serration and Bolt Holes - Inspect.................................................. 6-23
4.15
Connecting Rod Bearing - Inspect.......................................................................................... 6-23
4.16
Connecting Rod Bearing Thickness - Measure ...................................................................... 6-24
4.17
Connecting Rod Bend and Twist - Inspect ............................................................................. 6-24
5.
Crankcase and Crankshaft - Inspect and Repair ................................................ 6-25
5.1
Crankcase Top Surface Distortion - Measure......................................................................... 6-25
5.2
Inside Diameter of Main Bearing Housing Bore - Measure .................................................... 6-25
5.3
Cylinder Liner Fitting Bore in Crankcase - Inspect ................................................................. 6-25
6-1
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