Club Car Gasoline Service Manual page 219

2. Make the first measurement parallel with the crankshaft and the second at right angles to the crank-
shaft at three different locations in the bore. The first measurement location is 0.4 inch (10 millimeters)
from the top of the cylinder. The second location is in the center or 2.4 inches (60 millimeters) from the
top, and the third location is 0.3 inch (8 millimeters) from the bottom of the cylinder or bottom of ring
travel (See locations 1, 2, and 3 in Figure 13-55). The standard bore diameter is 3.0700 - 3.0708
inches (77.980 - 78.000 mm). The maximum cylinder bore diameter wear limit is 3.0735 inches (78.067
mm). The maximum acceptable out of round cylinder bore is 0.0022 inch (0.056 millimeter). If the cylin-
der bore is not within these measurements, the cylinder bore will need to be resized.
To Resize Bore to Next Oversize
Always resize either to exactly 0.010 inch (0.25 millimeter) or to exactly 0.020 inch (0.50 millimeter) over
standard size.
1. When the bore is resized to 0.010 inch over standard size, the new bore dimension is 3.0791 - 3.0799
inches (78.210 - 78.230 millimeters). When the bore is resized to 0.020 inch over standard size, the
new bore dimension is 3.0890 - 3.0898 inches (78.460 - 78.480 millimeters) (See Specifications for
Resizing Cylinder Bore Table, Page 13-49).
NOTE
• ALLOW FOR A SHRINKAGE (FROM THE FINAL SIZE) OF 0.0003-0.0004 INCH (0.007-0.009 MIL-
LIMETERS) WHICH WILL OCCUR WHEN THE CYLINDER COOLS DOWN.
2. Hone the cylinder that is to be 0.010 inch over standard size so that the final bore size diameter is
3.0799 - 3.0807 inches (78.230 - 78.250 millimeters). The final honed bore diameter for a 0.020 inch
over standard size bore is 3.0898 - 3.0906 inches (78.480 - 78.500 millimeters) (See Specification for
Resizing Cylinder Bore Table, Page 13-49).
NOTE
• IMPORTANT: THE CYLINDER WALL FINISH SHOULD HAVE A 40° TO 60° CROSS-HATCH PAT-
TERN. DO NOT USE SOLVENTS OR GASOLINE (FIGURE 13-56).
3. After honing, clean the cylinder wall thoroughly using soap, warm water and clean rags.
MEASURE EACH LEVEL
IN BORE AT 2 PLACES
90° APART
1
3
1
3
FIGURE 13-55
1
2
3
HONING
TOOL
FIGURE 13-56
Page 13-29
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