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2. Obtain a three blade rigid hone with 220 grit
aluminum oxide stones.
3. To prevent damage to stones, check the top and
bottom of the cylinder bore for burrs. Remove any
burrs with a fine-tooth file.
4. Securely fasten cylinder to a heavy iron bracket or
suitable honing fixture and place on level floor.
5. Place hone drive shaft in chuck of portable, variable
speed drill and tighten.
6. Using a suitable honing oil, liberally lubricate cylinder
bore and stones.
7. Place hone in middle of cylinder bore.
8. Tighten adjusting knob until stones fit snugly against
cylinder wall.
9. Activate drill and move hone up and down lower
end of cylinder bore. The cylinder is not worn at the
bottom, so it will help to keep hone straight in the
bore. As the bottom of the bore increases in diameter,
gradually increase each stroke until hone travels the
full length of the bore.
NOTE: Hone cylinder bore with a drill speed of 300 to
700 RPM maximum at 40-60 strokes per minute.
NOTE: Do not extend hone more than 3/4-1 inches
(19.05-25.4 mm) from either end of the bore or stones
may be damaged.
10. As cutting tension decreases, stop hone and tighten
adjusting knob.
11. Frequently stop to examine the cylinder bore and take
measurements.
NOTE: Hone cylinder bore about 0.0005 inches
(0.01 mm) larger than the desired size to allow for
contraction as the cylinder cools.
12. Lubricate hone frequently to prevent build up on
stones.
13. Stop frequently to examine the cylinder bore and take
measurements.
14. When cylinder is resized to within 0.0015 inches
(0.04 mm) of the desired size, use finishing stones to
achieve the final size and produce the correct cross
hatch pattern. See Deglaze (Recondition) Cylinder
Bore, steps 3-7.
NOTE: An improper cross hatch pattern or too fine
a hone will result in insufficient oil retention and
possible piston seizure and/or high oil consumption.
Clean Crankcase and Cylinder Bore
1. Thoroughly wash crankcase and cylinder bore with a
non-volatile cleaning solution or solvent.
2. To loosen all abrasive particles and residual grit,
thoroughly scrub cylinder bore with a stiff bristle brush
using liquid dishwashing soap and hot water.
3. Thoroughly rinse cylinder bore with hot running water.
4. Repeat washing and rinsing until all traces of honing
grit are gone. Continue cleaning until a clean cloth
shows no evidence of dirt or debris.
NOTE: Honing grit, which appears as a grey residue,
is highly abrasive and will cause rapid cylinder, piston
and ring wear resulting in premature engine failure.
5. Hot rinse the crankcase and dry with moisture free
compressed air.
6. Verify that breather passage, intake and exhaust
ports, and governor gear assembly are completely
clean and free of dirt and grit.
7. Verify that oil hole between the tappet bores is clean
and open.
8. Lightly lubricate cylinder bore with clean engine oil.
Assembly
Crankcase
MAG Bearing/Oil Seal
1. Feel bearing bore for smoothness. Use fine steel
wool or crocus cloth to remove any burrs or minor
imperfections.
2. Apply a thin film of clean engine oil to bearing bore
and OD of new bearing.
3. With the inside facing upward, support crankcase on
wooden blocks on deck of arbor press.
4. With the bearing manufacturer's identification facing
the inside of the crankcase, place bearing into
bearing bore.
80
6
63
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