Section 03 787 RFI ENGINE
Subsection 03 (TOP END)
INSPECTION
Refer to table below to find top end engine dimen-
sion specifications. For dimension measurement
procedures, refer to ENGINE MEASUREMENT.
Visually inspect all parts for corrosion damage.
Inspect piston for damage. Light scratches can be
sanded with a fine sand paper.
NOTE:
When repairing a seized engine, connect-
ing rods should be checked for straightness and
crankshaft for deflection/misalignment.
Inspect plane surfaces for warpage. Small defor-
mation can be corrected by grinding surface with
a fine sand paper. Install sand paper on a surface
plate and rub part against oiled sand paper.
TOLERANCES
ENGINE
MEASUREMENT
NEW PARTS
(min.)
(max.)
WEAR
LIMIT
Combustion
chamber volume
34.7 cc
37.9 cc
N.A
Cylinder taper
N.A.
0.05 mm
(.002 in)
0.1 mm
(.004 in)
Cylinder out of
round
N.A.
0.008 mm
(.0003 in)
0.08 mm
(.003 in)
Piston skirt
N.A.
N.A.
0.12 mm
(.005 in)
Piston/cylinder
wall clearance
0.13 mm
(.005 in)
N.A
0.24 mm
(.009 in)
Ring/piston
groove clearance
0.025 mm
(.001 in)
0.070 mm
(.0027 in)
0.24 mm
(.009 in)
Ring end gap
0.40 mm
(.016 in)
0.55 mm
(.022 in)
1.0 mm
(.039 in)
N.A.: NOT APPLICABLE
NOTE:
Replacement cylinder sleeves are available
if necessary. Also, oversize pistons of 0.25 mm
(.010 in) are available.
RAVE Valve
Check RAVE valve bellows
no. 21
for cracks.
Check sliding valve for wear, bent or other dam-
ages.
ASSEMBLY
Assembly is essentially the reverse of disassem-
bly procedures. However pay particular attention
to the following.
RAVE Valve
Make sure to insert O-ring
no. 23
onto rod of slid-
ing valve
no. 22
.
The TOP position of the sliding valve
no. 22
is
indicated on one side.
F01D8KA
1
3
2
1. Sliding valve
2. O-ring
3. TOP
Install a new gasket
no. 24
. It must be installed
at the same time as the sliding valve
no. 22
.
Position the valve housing
no. 25
onto the cylinder
so that its opening is toward the bottom.
F01D8JB
1
1. Bottom of valve housing
When the valve is mounted onto the cylinder,
move the valve piston
no. 20
to ensure the sliding
valve
no. 22
moves easily and does not stick.
80
smr2005-082
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