Cylinder / Piston Service Information; Cylinder / Piston Service Data; Cylinder / Piston Torque Values; Cylinder / Piston Troubleshooting - Sachs Bikes madass Repair Instructions

CYLINDER / PISTON
SERVICE INFORMATION
GENERAL
- This section covers the Service of the piston and cylinder. These Services are completed with the engine in the frame.
- The camshaft lubricating oil is fed to the cylinder head through an oil orifi ce in the right crankcase. Be sure this orifi ce is not
clogged and that the O-ring and dowel pins are in place before installing the cylinder.
SERVICE DATA
ITEM
Cylinder
Piston
Piston pin
Piston ring End gap
Piston-to-ring
groove clearance
Connecting rod small end
TORQUE VALUES
Cylinder bolt
Cam chain guide roller pin bolt
TROUBLESHOOTING
Low or unstable compression
- Worn cylinder or piston rings
Excessive smoke
- Worn cylinder, piston or piston ring
- Improper Installation of piston rings
- Scored or scratched piston or cylinder wall
Overheating
- Excessive carbon build-up on piston or combustion cham-ber wall
Knocking or abnormal noise
- Worn piston and cylinder
- Excessive carbon build-up
110
I.D.
Warpage
Out of round
Taper
O.D.
Piston pin bore
Cylinder-to-piston clearance
O.D.
Piston-to-pin clearance
Top/second
Oil (side rail)
Top
Second
I.D.
Small end-to-piston pin
clearance
10-12 Nm
10 Nm
STANDARD SERVICE LIMIT
39.005-39.01 5
—
—
—
38.975-38.995
13.002-13.008
0.010-0.045
12.994-13.000
0.002-0.014
0.15-0.35
0.30-0.90
0.015-0.050
0.015-0.050
13.016-13.034
0.016-0.040
Unit: mm
39.05
0.05
0.10
0.10
38.90
13.05
0.15
12.98
0.08
0.5
1.1
0.12
0.12
13.06
0.08