Service manual

ENGINE MEASUREMENTS
Page C-2
Engine Shop Rebuild and Parts Manual
F. Turn the cylinder head so that the valve cover gasket
surface rests on the surface plate. Check for flatness.
Crankcase Cylinder Bores
(See Fig. C-3 “Crankcase Cylinder Bores” on page C-4)
A. Use a telescoping gauge to measure each cylinder
bore at three (3) positions (DIMENSIONS A, B, AND
C), in two (2) places each, 90° apart as shown.
B. Inspect the cylinder wall surfaces for proper cross-
hatched finish. (DETAIL A)
Crankcase and End Cover Crankshaft Bear-
ing Bores
(See Fig. C-4 “Crankshaft Journals and Gear, and Bearing Bores” on
page C-5)
A. Using a telescoping gauge, measure the crankshaft
bearing bores in the crankcase (DIMENSION A,B) in
two (2) places, 90° apart.
B. Using a telescoping gauge, measure the crankshaft
bearing bore in the end cover (DIMENSION C) in two
(2) places, 90° apart.
Crankshaft Journals and Gear
(See Fig. C-4 “Crankshaft Journals and Gear, and Bearing Bores” on
page C-5)
Measure crankshaft rod journals away from the
oil holes in the journals.
A. Measure the rod and bearing journal diameters
(DIMENSIONS A, B, C, D, E, AND G), in two (2)
places each, 90° apart. If rod journals are excessively
rough, scored or out of round, replace the crankshaft.
Minor scratches on journals can be carefully polished
using extra fine emery cloth. Thoroughly clean crank-
shaft after polishing and reinspect journal diameters.
B. Measure the oil seal surface diameters (DIMEN-
SIONS H AND J) in two places each, 90° apart.
Inspect for wear, roughness, or pitting. Replace
crankshaft if below specified limit.
C. If the bearing was removed from the crankshaft, mea-
sure the bearing journal (DIMENSION F) in two
places, 90° apart.
D. Inspect gear teeth and oil seal areas for excessive
wear or damage.
E. Inspect oil passage plug in end of crankshaft for dam-
age.
Crankcase and End Cover Balancer Shaft
Bearing Bores
(See Fig. C-6 “Balancer Shaft Journals, Gear and Bearing Bores” on
page C-7)
A. Use a telescoping gauge to measure the balancer
shaft bearing bore in the crankcase (DIMENSION A)
in two (2) places, 90° apart.
B. Use a telescoping gauge to measure the balancer
shaft bearing bore in the end cover (DIMENSION B)
in two places, 90° apart.
Balancer Shaft Journals and Gear
(See Fig. C-6 “Balancer Shaft Journals, Gear and Bearing Bores” on
page C-7)
A. Measure the bearing journal diameters (DIMEN-
SIONS A AND B) in two places each, 90° apart.
Inspect gear teeth and oil seal areas for excessive
wear or damage.
Piston
(See Fig. C-5 “Piston, Wrist Pin and Connecting Rod” on page C-6)
A. Measure wrist pin bore (DIMENSION A) at two (2)
places, 90° apart.
B. Measure piston skirt (DIMENSION B) as shown.
C. Measure piston ring grooves (DIMENSIONS C AND
D) at several positions around the piston.
Fig. C-2 Flatness of Mating Surfaces
feeler
guage
surface
plate