Kohler SV810-840 Service Manual page 108

Section 9
Inspection and Reconditioning
Inspect the crankpin for score marks or metallic
pickup. Slight score marks can be cleaned with crocus
cloth soaked in oil. If wear limits, as stated in Section
Crankcase
Inspection and Service
Check all gasket surfaces to make sure they are free of
gasket fragments. Gasket surfaces must also be free of
deep scratches or nicks.
Check the cylinder bore for scoring. In severe cases,
cylinder wall. It washes the necessary lubricating
seeps down the cylinder wall, the piston rings make
metal to metal contact with the wall. Scoring of the
cylinder wall can also be caused by localized hot
inadequate or contaminated lubrication.
If the cylinder bore is badly scored, excessively worn,
tapered, or out-of-round, resizing is necessary. Use an
inside micrometer to determine the amount of wear
A 0.25 mm (0.010 in.) oversize piston is available if
resizing is selected. Initially, resize using a boring
bar, then use the following procedures for honing the
cylinder.
Honing
While most commercially available cylinder hones
can be used with either portable drills or drill presses,
the use of a low speed drill press is preferred as it
facilitates more accurate alignment of the bore in
accomplished at a drill speed of about 250 RPM and
hone, proceed as follows:
so that the stones are in contact with the cylinder
recommended.
2. With the lower edge of each stone positioned
even with the lowest edge of the bore, start drill
and honing process. Move the hone up and down
ridges. Check the size frequently.
9.2
NOTE: Kohler pistons are custom-machined to
exacting tolerances. When over-sizing a
cylinder, it should be machined exactly
0.25 mm (0.010 in.) over the new diameter
oversize Kohler replacement piston will then
3. When the bore is within 0.064 mm (0.0025 in.) of
the desired size, remove the coarse stones and
replace them with burnishing stones. Continue
with the burnishing stones until the bore is
within 0.013 mm (0.0005 in.) of the desired size
should be observed if honing is done correctly.
The crosshatch should intersect at approximately
cause the rings to skip and wear excessively,
and too steep an angle will result in high oil
consumption. See Figure 9-1.
Figure 9-1. Cylinder Bore Crosshatch After
Honing.
taper, and size. Use an inside micrometer,
telescoping gauge, or bore gauge to take
measurements. The measurements should be
taken at three locations in the cylinder – at the
should be taken (perpendicular to each other) at
each of the three locations.
Clean Cylinder Bore After Honing
Proper cleaning of the cylinder walls following boring
and/or honing is very critical to a successful overhaul.
rebuild.
(220-280 grit) and