Cylinder - wsm RTV900 Workshop Manual

RTV900, WSM

(5) Cylinder

Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.'s.
2. Get the difference (maximum wear) between the maximum and
the minimum I.D.'s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension.
4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored.
Factory spec.
Cylinder Liner I.D.
Allowable limit
(A) Top
(B) Middle
(C) Bottom (Skirt)
Correcting Cylinder
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
Factory spec.
Cylinder I.D.
[Oversize]
Allowable limit
Horn to 1.2 to 2.0 μm Rmax.
∇∇∇∇
Finishing
(0.000047 to 0.000079 in. Rmax.)
2. Replace the piston and piston rings with oversize ones.
Oversize Part Name
Piston
0.25 mm
0.0098 in.
Piston ring assembly
NOTE
• When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1) Cylinder I.D.
[Before Correction]
1-S52
ENGINE
72.000 to 72.019 mm
2.83464 to 2.83539 in.
72.150 mm
2.84055 in.
(a) Right-angled to Piston Pin
(b) Piston Pin Direction
W1051440
72.250 to 72.269 mm
2.84449 to 2.84524 in.
72.400 mm
2.85040 in.
Code Number Marking
1G962-21900 025
1G460-21090 025
(2) Cylinder I.D. [Oversize]
W1051790
KiSC issued 03, 2008 A