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5 HP Outboard • Troubleshooting & Repair Manual
Section 4 • Overhaul
Hone Cylinder
1. Place hone in middle of cylinder bore. Tighten
adjusting knob with finger or small screwdriver until
stones fit snugly against cylinder wall. Do not force.
2. Install drive shaft to drill chuck. Connect drive shaft to
hone. Be sure that cylinder and hone are centered and
aligned with drive shaft and drill spindle.
3. Lubricate honing stones and cylinder bore with honing
oil or automatic transmission fluid.
Recommended drill speed is 300-700 RPM maximum and
40-60 strokes per minute. Lubricate hone frequently to
prevent build-up on stones. The cylinder will show the most
wear in the ring travel area
(Figure 75)
does not wear oversize or out-of-round below the ring
travel area
and will guide the hone to straighten cylinder
2
bore.
4. Start the drill and, as the hone spins, move it up and
down limiting the travel to the bottom of the cylinder
.
(Figure 75)
3
Figure 75 — Cylinder Honing Details
B
2
4
4
C
4
5. As the bottom of the cylinder increases in diameter,
gradually increase the length of the strokes until hone
travels full length of bore and extends past the
cylinder bore ends
.
4
. The cylinder
1
1
3
Do not extend hone more than 3/4 - 1" (19mm - 25mm) at
either end of cylinder bore
6. As cutting tension decreases, stop hone and tighten
adjusting knob.
7. Check cylinder bore frequently with an accurate
micrometer.
Cylinder Finish ("Cross Hatch")
The finishing stones are used after the cylinder bore has
been resized to within .0015" (.04mm) of the desired size
or when reconditioning a cylinder bore. The finishing stones
produce the correct cross hatch necessary for proper
lubrication. Correct cross hatch angle is approximately 45
degrees
.
(Figure 76)
Figure 76 — Cylinder Finish
It is recommended that the cylinder bore be reconditioned
to restore the cross hatch when new piston rings are to be
installed to a cylinder that is within specification. Do not
hone oversize or it will be necessary to resize the cylinder.
NOTE:
To produce the proper cross hatch finish
use a drill speed of approximately 200 RPM and
40-60 strokes per minute. Lubricate hone liberally to
prevent build up on finishing stones.
43
.
4
4
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