Service manual
Table Of Contents
(4) When the sleeves are worn beyond the service limit,
or when any cylinder bore
is
found to be defective,
the sleeve should be replaced with a new one.
When the inside surfaces
of
one
of
more cylinder
bores in the crankcase are found
to
be defective,
it
is
necessary
to
refinish the bores
by
boring.
In this case,
too,
the liners should be replaced with
new ones. To replace, proceed
as
follows:
(a) Removal
e Fix a boring machine
to
the crankcase in alignment
with the cylinder bore from which a sleeve
is
to be
removed. Aligning should be made at the
bottom
part
of
the liner where
less
abnormal wear has
occurred.
• Bore the sleeve until it reaches 0.5 mm (0.0197 in.)
in stock thickness.
• Break the sleeve, exercising care not to damage the
inside surface
of
the cylinder bore.
(b) Installation
It
Visually check the inside surfaces
of
the cylinder
bores for condition.
It
is
necessary
to
rebore the
bores
if
they are damaged.
e When
it
is
unnecessary
to
reb ore the cylinder
bores, proceed
as
in steps below.
• Measure. the diameter
of
cylinder bore and the
outside diameter
of
sleeve. Select oversize sleeve
so
that the clearance between the sleeve and the bore
is
0.08 mm (0.0031 in.) to 0.145 mm (0.0057 in.).
Heat the crankcase
to
about 300°C (572°F).
Press the sleeve into the bores
in
the crankcase by
using a hydraulic press in such a manner to make
the top
of
sleeve protrude by 0.3 to 0.5 mm (0.012
to 0.020 in.) from the crankcase. Then, finish them
to
be
flush with the crankcase.
After pressing the sleeves, rebore and hone them to
th
t
84
+0.035
(3307
+0.0014. )
em a 0
mm.
0
tn
..
Pressing sleeve
• When
it
is necessary
to
rebore the cylinder bores,
press the sleeves into position
as
in
b above, and
proceed
as
follows:
Prepare 0.5
mm
(0.0197 in.) oversize cylinder
sleeves.
Rebore the cylinder bores so
that
the clearance
between the sleeve and the bore
is
0.08 mm
(0.0031 in.)
to
0.145 mm (0.0057 in.).
After pressing the sleeves, rebore and hone them to
th
t 84 +0.035
(3307
+0.0014. )
em a 0
mm.
0 m
..
Specifications
Unit·
mm
(in )
Cylinder sleeve
Sleeve
boring dimension
Standard
87
-0.010
(3 425
-0.0004)
-0.045
.
-0.0018
0.5 -oversize
875-
0
.
010
(3
445
-0.0004)
.
-0.045
.
-0.0018
When replacing the sleeves, use the sleeves
of
the
following part numbers.
Specifications
Unit:
mm (in.)
Part
No.
0.0.
1.0. Remarks
87+
0
.10
83.5
0
30607-50301
+0.07
-0.2
Standard
(3 425 +0.0004)
0
. +0.0028
(3.287_
0
.
008
)
875+
0
.
10
83.5
0
30607-50401
. +0.07
-0.2
Oversize
(3445
+0.0004)
0
. +0.0028
(3.287
-0.008)
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