5.

Maintenance Section

Cylinder Bore diameter and machining guidelines:

1. Mount the crankcase to the overhauling stand
2. Clean the cylinder bore with clean cloth. Ensure it is free from oil & dust..
3. Using Bore dial gauge, measure cylinder bore diameter on both thrust & non-thrust sides
4. Draw a table as shown below to calculate the taper & Ovality of the cylinder bore.
5. If the taper or Ovality is above the specified limit, machine the cylinder bore to the next oversize.
Follow the machining guidelines as given below without fail.

Service Procedure
DICV-OM906-7598

Measurement Description Equipment Used Specifications

Cylinder Bore diameter Bore dial gauge Standard Ref below table

Deviation of cylinder bore from the cylindrical form 0.012mm

Type of Block
Pistons to be used Standard Bore Inter-
Machining Tolerance (check this on the side for the block types nal diameter in mm
of block)

+0.015- +0.009 C BC 102.015- 102.009

±0.008 B BC & BA 102.008- 101.992

-0.009- -0.015 A BA 101.991- 101.985

Notice
Please ensure that whenever crankcase height is reduced, the cylinder bore dia need to be increased to
the next over size or when the cylinder bore dia. is machined to next over size, the crankcase height
need to be reduced to the next under size. Pl. refer table for the same.

This is to ensure the total volume of cylinder is maintained as per the requirements.

2-103 Service Manual - Engine