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9. CYLINDER/PISTON

9-0

XCITING 500

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CYLINDER/PISTON

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SCHEMATIC DRAWING ------------------------------------------------- 9-1

SERVICE INFORMATION------------------------------------------------ 9-2

TROUBLESHOOTING----------------------------------------------------- 9-2

CYLINDER/PISTON REMOVAL---------------------------------------- 9-3

CYLINDER/PISTON INSTALLATION--------------------------------- 9-7

Summary of content (10 pages)

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9. CYLINDER/PISTON XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed. • After disassembly, clean the removed parts and dry them with compressed air before inspection. SPECIFICATIONS Item I.D. Warpage Cylinder Cylindricity True roundness Ring-to-groove clearance Piston, piston ring .
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9. CYLINDER/PISTON CYLINDER/PISTON REMOVAL XCITING 500 Bolts Cylinder/Gasket Block Pin Remove the cylinder head (page 8-11). Take the block pin out. Remove the water hose from the cylinder. Remove the two cylinder bolts. Remove the cylinder and gasket. Water Hose Dowel Pins Remove the dowel pins Dowel Pins Piston Pin Clip Remove the piston pin clip. ＊ Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase.
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9. CYLINDER/PISTON XCITING 500 Spread each piston ring and remove it by lifting up at a point opposite the gap ＊ Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves. INSPECTION Piston ring Inspect the piston rings for movement by rotating the rings. The rings should be able to move in their grooves without catching. Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring-to-groove clearance.
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9. CYLINDER/PISTON Piston/Piston pin Measure the piston O.D. at the point 10 mm from the bottom and 90° to the piston pin hole. Service Limit: 91.9 mm (3.676 in) Calculate the cylinder-to-piston clearance (cylinder I.D.: page 9-6) Measure the piston pin hole. Take the maximum reading to determine the I.D.. Service Limit: 22.04 mm (0.8826 in) Measure the piston pin O.D. at piston and connecting rod sliding areas. Service Limit: 21.96 mm (0.8784 in) Measure the piston-to-piston pin clearance.
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9. CYLINDER/PISTON XCITING 500 Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Service Limit: 0.05 mm (0.002 in) Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis. Take the maximum reading to determine the cylinder wear. TOP MIDDLE Service Limit: 92.1 mm (3.684 in) Calculate the piston-to-cylinder clearance. Take a maximum reading to determine the clearance.
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9. CYLINDER/PISTON Measure the connecting rod small end I.D.. Service Limit: 22.06 mm (0.8824 in) Calculate the connecting rod-to-piston pin clearance. Service Limit: 0.06 mm (0.002 in) CYLINDER/PISTON INSTALLATION PISTON RING INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing up. ＊ Be careful not to damage the piston and rings. Do not confuse the top and second rings. To install the oil ring, install the oil ring, then install the side rails.
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. CYLINDER/PISTON CYLINDER/PISTON INSTALLATION Clean any gasket material from the cylinder mating surfaces of the crankcase and oil passage. XCITING 500 Piston “IN” Mark Apply engine oil to the piston pin. Apply engine oil to the connecting rod small end and piston pin hole. Install the piston with the “IN” mark face intake side and piston pin. Piston Pin Piston Pin Clip Place a clean shop towel over the crankcase prevent the clip from falling into the crankcase. Install the new pin clip.
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9. CYLINDER/PISTON Install the gasket. XCITING 500 Bolts Cylinder/Gasket Block Pin Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Pass the cam chain through the cylinder and install the cylinder over the piston. ＊ Be careful not to damage the piston rings and cylinder walls. Install and tighten the two cylinder bolts to specified torque. Torque: 10 N•m (1 kgf•m, 7 lbf•ft) Install the block pin. Connect the water hose.