Boring And Honing Cylinder - Buell 2002 X1 Handbook

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Boring and Honing Cylinder

When cylinder requires oversize reboring to beyond 0.030 in.
(0.762 mm), the oversize limit has been exceeded and cylin-
der must be replaced.
1. Bore cylinder with gaskets and torque plates attached.
Bore to 0.003 in. (0.076 mm) under the desired finished
size.
2. Hone the cylinder to its finished size using a 280 grit rigid
hone followed by a 240 grit flexible ball hone. Honing
must be done with the torque plates attached. All honing
must be done from the bottom (crankcase) end of the
cylinder. Work for a 60° crosshatch pattern.
Fitting Piston Rings
NOTE
Ring sets and pistons, 0.040 in. (1.016 mm) oversize, are not
available on 1200cc engines.
See Figure 3-35. Piston rings are of two types: compression
(1, 2) and oil control (3). The two compression rings are posi-
tioned in the two upper piston ring grooves. The dot on the
second compression ring must face upward. Ring sets are
available to fit standard and oversize pistons.
Piston ring sets must be properly fitted to piston and cylinder:
1. See Figure 3-36. Place piston in cylinder about 1/2 in.
(12.7 mm) from top. Set ring to be checked squarely
against piston as shown. Check end gap with thickness
gauge. See 3.1 SPECIFICATIONS
NOTE
See SERVICE WEAR LIMITS
not file rings to obtain proper gap.
6612
1
2
1. Top Compression Ring – Install either side up
2. Second Compression Ring – Install dot toward
top
3. Oil Control Rings
Figure 3-35. Piston Rings
3-26
for tolerance.
for end gap dimensions. Do
3
Dot
Table 3-8. Final Cylinder Bore Sizes
BORE SIZES
Standard bore* 3.4978 in.
0.005 in. OS bore
3.502 in.
(0.127 mm)
0.010 in. OS bore
3.507 in.
(0.254 mm)
0.020 in. OS bore
3.517 in.
(0.508 mm)
0.030 in. OS bore
3.527 in.
(0.762 mm)
*All bore sizes + 0.0002 in. (0.0051 mm)
2783a
Figure 3-36. Measuring Ring End Gap
IN. MM
88.8441 mm
88.951 mm
89.078 mm
89.332 mm
89.586 mm
2002 Buell X1: Engine