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7.
CYLINDER HEAD/CYLINDER/PISTON
SERVICE INFORMATION
TROUBLESHOOTING
SERVICE INFORMATION
GENERAL
7-1
7-2
CYLINDER HEAD
CYLINDER,
PISTON
7-3
7-5
This
section covers service
of the
cylinder
head,
cylinder
and piston. These procedures
can
be done with the engine
in
the frame.
Before disassmbling,
clean
the
engine
thoroughly to keep din from
entering
the engine.
Do not use a screwdriver to remove the cylinder head.
Clean all disassembled parts with cleaning
solvent
and dry them by blowing them off
with
compressed
air
before
inspection.
Before assembling, apply clean Pro-Honda HP2 2·stroke Oil to all
sliding
surfaces.
Under racing conditions. the piston and
piston
rings
should
be replaced after 7.5 hours
of
funning. Replace the piston
pin
and connecting
rod small
end
bearing after 22.5 hours of running.
Refer to
section
4
for reed valve
servicing.
Refer to section 8 for
RC
valve system decarbonizing, disassembly and assembly.
SPECIFICATIONS
Unit: mm
(in)
ITEM
STANDARD
SERVICE
LIMIT
Cylinder head warpage
- -
0.05
(0.002)
Cylinder
1.0.
A
53.916
-
53.983
(2.
1250
-
2.1253)
54.013
(2.1265)
B
53.968
53.976(2.1247
2.1250)
54.006
(2. 1262)
Out
of
round
- -
0.05
(0.002)
Taper
- -
0.05
(0.002)
Warpage
- -
0.05
(0.002)
Piston, piston
Piston mark direction
~IN~
mark facing
toward
the intake side
- -
rings
Piston 0.0.
A
53.933
-
53.940
(2.
1233
-
2.1236)
53.883
(2.1214)
B
53.925
-
53.933
(2.
1230
-
2.1233)
53.875
(2.1211)
Piston 0.0. measurement point
15 mm
(0.59
in) from bottom of
skirt
- -
Piston pin bore 1.0.
15.002
-
15.015 (0.5906
-
0.5911)
15.035
(0.5919)
Piston pin
O.D.
14.994
-
15.000
(0.5903
-
0.5906)
14.98 (0.590)
Piston-to-piston pin
clea
rance
0.002
-
0.021
(0.000
1
-
0.0008)
0.03 (0.001)
Piston
ring-to-ring groove clearance
0.045
-
0.080
(0.002
-
0.003)
0.09
(0.004)
Piston
ring end gap
0.40
-
0.55
(0.016
-
0.022)
0.65 (0.026)
Cylinder-to-piston clearance
0.035
-
0.050
(0.0014
-
0.0020)
0.07
(0.003)
Connecting
rod
small end I.D.
19.002
-
19.014
(0.748
1
-
0.7486)
19.022
(0.7489)
7-1
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- Torque Values
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