Installation Instructions
B1700·B2100·B2400
W5M,11770
(5) Cylinder
1 ENGINE
0087F074
UX(b)
\J9---(a)
Er
CD
®
®
Wear
of
Cylinder
1.
Measure
the
cylinder inner
diameter
using
the
cylinder
gauge at
six
points shown in the figure (directions
(a)
and (b)
at
points (1), (2) and (3». Calculate difference between the
maximum and minimum measured values. In
general,
maximum wear appears
at
direction
(a)
or (b)
of
point
(1)
which
is
about
20
mm
(0.787 in.) from the
top
edge
while
minimum wear
is
at
direction
(a)
or (b)
of
point
(3).
2.
If
the
calculated difference exceeds
the
allowable
limit
specified in the table below, install
the
oversized piston and
piston ring.
(a)
At
a
right
angle
to
the
piston pin
(b)
In
the
direction
of
the
piston pin
(1) Top
(About
20
mm (0.787 in.)
from
the
top
edge)
(2)
Middle
(About
40
mm,
1.575 in.)
(3) Bottom
(About
100
mm,3.937
in.)
~.5236
fad
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CD
.
®
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B083F061
----
Model
Factory
spec.
Allowable
limit
D905
72.000
to
72.019 mm 72.169 mm
2.83465
to
2.83539 in. 2.84130 in.
Wear
of
D1005
76.000
to
76.019 mm 76.169 mm
cylinder
I.D.
2.99213
to
2.99289 in. 2.99878 in.
D1105
78.000
to
78.019 mm 78.169 mm
3.07087
to
3.07161 in. 3.07752 in.
Correcting Cylinder
1.
Bore and finish the cylinder inner wall using a hone
to
a
diameter +
0.5
mm
(0.0197 in.) larger than the standard.
The
surface roughness after honing must
be
1.2
to
2.0
,uRz.
I'll NOTE
.. Chamfer the
top
corner (A)
of
the
cylinder
as
shown
to
protect the piston ring from being damaged when inserting
the piston
into
the cylinder.
----
Model
Cylinder I.D.
Finishing
D905
72.500
to
72.519 mm
2.85433
to
2.85508 in.
Oversized
D1005
76.500
to
76.519 mm Hone
to
1.2
to
2.0
cylinder 3.01181
to
3.01256 in.
,uRz
D1105
78.500to
78.519 mm
3.09055
to
3.09129 in.
I'll IMPORTANT
.. When
the
oversized cylinder
liner
is
worn
beyond
the
allowable
limit,
replace the cylinder liner and bore and hone
it
.
•
The
cylinder liner which
has
been oversized should use a
piston and a ring assembly
of
the
same oversize.
Code No,
Mark
Oversize Part name D905 D1005
D1105
Piston
05
16221-2191-0
16251-2191-0 16281-2191-0
0505
0.5mm
Piston 2
05
- -
(,-
0.0197 in.
Piston ring assembly 05 15901-2109-0 16271-2109-0
16261-2109-0
1-543