Deglazing Cylinder; Fitting Piston Rings - Buell XB 2008 Series Service Manual

NOTE
If cylinder clearance exceeds service wear limit, cylinders and
pistons should be replaced with new components. See
3.1 SPECIFICATIONS.
Table 3-20. Cylinder Bore Service Wear Limit
STANDARD BORE
XB models
sm00160
Figure 3-76. Measuring Cylinder Bore Using Torque Plates
(Part No. HD-33446B)

Deglazing Cylinder

NOTE
Deglazing removes wear patterns, minor scuff marks and
scratches without enlarging the bore diameter.
1. Lightly swab the cylinder bore with a cloth dipped in clean
engine oil.
2. Obtain a 240 grit flexible ball-type deglazing tool with a
bristle tip or finishing stone arrangement able to produce
a 60° cross hatch pattern.
3. Install the deglazing tool in a slow-speed drill. The speed
at which the tool rotates determines the speed at which it
must be stroked up and down the bore to produce the
desired cross hatch pattern.
4. Starting at the bottom of the cylinder, move the deglazing
tool up and down the entire length of the cylinder bore for
10 to 12 complete strokes.
3-52 2008 XB Service: Engine
IN. MM
3.5008 88.9203
NOTES
Stop to examine the cylinder bore and/or take measure-
ments. A precise 60° cross hatch pattern in the piston
travel area is the most important.
The angular cross hatch pattern ensures an even flow of
oil onto the cylinder walls and promotes longer cylinder,
piston and ring life. An Improper crosshatch pattern will
result in insufficient oil retention and possible piston
seizure and/or high oil consumption.
Failure to remove all abrasive particles may result in pre-
mature cylinder, piston and ring wear and possible engine
failure.
5. Thoroughly wash the cylinder bore with liquid dishwashing
soap and warm water to remove all abrasive particles and
residual grit. Continue cleaning until a clean cloth shows
no evidence or dirt or debris.
6. Hot rinse the cylinder and dry with moisture free com-
pressed air.
7. Immediately apply a thin film of clean engine oil to a clean
white paper towel and thoroughly wipe the inside of the
cylinder.
NOTE
After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.
8. With the cylinder at room temperature, check the cylinder
clearance. See 3.1 SPECIFICATIONS.

FITTING PISTON RINGS

PART NUMBER
J-5586-A TRANSMISSION SHAFT RETAINING
RING PLIERS
NOTE
See Figure 3-77. 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 (4) on the
second compression ring must face upward.
1. See Figure 3-78. Insert the new ring into the cylinder,
square it in the bore using the top of the piston and
measure the ring end gap with a feeler gauge. Do not use
the ring if the end gap does not fall within the following
specifications, refer to Table
NOTES
The same piston may be used if cylinder bore was not
changed, unless it is scuffed or grooved. If re-using piston,
replace piston rings and hone the cylinder walls with a No.
240 grit flexible hone to facilitate ring seating.
Piston ring sets must be properly fitted to piston and cyl-
inder.
2. See Figure 3-79. Apply engine oil to piston grooves. Install
rings on piston starting with the oil ring, second compres-
sion ring, then the top ring. Use TRANSMISSION SHAFT
RETAINING RING PLIERS (Part No. J-5586-A) to slip
compression rings over piston into their respective
grooves. Be extremely careful not to over expand, twist
rings or damage piston surface when installing rings.
TOOL NAME
3-21.