ENGINE MEASUREMENTS ENGINE MEASUREMENTS AND SPECIFICATIONS CYLINDER HEAD. Measure Cylinder Compression. Using Telescoping Gauges and Hole Gauges

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1 ENGINE MEASUREMENTS AND SPECIFICATIONS Tool List Qty. Required Compression Gauge, 20 kgf/cm²: E-Z-GO Part No. N/A... 1 Compression Gauge Adapter, M : E-Z-GO Part No. N/A... 1 Valve Seat Cutter, E-Z-GO Part No Valve Seat Cutter, E-Z-GO Part No Valve Seat Cutter, E-Z-GO Part No Valve Seat Cutter, E-Z-GO Part No Valve Seat Cutter Holder, 7 E-Z-GO Part No Valve Seat Cutter Holder Bar E-Z-GO Part No C Telescoping gauges and hole gauges are transfer-type measuring instruments. They are not calibrated and are used to record a distance, which is then transferred to a micrometer for measurement. Position the gauge in the hole or bore and set the telescoping arms or ball to its true diameter. Make sure that the handle of the gauge is in line with the centerline of the hole or bore. Lock and remove the gauge. Measure its setting with a micrometer. CYLINDER HEAD Measure Cylinder Compression Thoroughly warm up the engine so that the engine oil between the piston and the cylinder wall will help seal compression as it does during normal running. B. All engine parts must be thoroughly cleaned, and free of all dirt, oil, grease, carbon deposits or residue of any kind before beginning this section. It is especially important that your work area be clean and well organized while performing the operations described in this section. In some cases, time may be saved by setting measuring instruments at limit specifications and using them as go-no-go fixtures. Check preset instrument fit in bores, on shafts, etc. to determine part acceptability. We recommend that parts bound to be acceptable but near limits be replaced if the engine will see high usage. Check micrometers for proper calibration before beginning the operations described in this section. Using Telescoping Gauges and Hole Gauges Stop the engine, remove the spark plug, and attach a compression gauge [A] firmly into the spark plug hole [B]. Special Tools Compression Gauge, 20 kgf/cm² E-Z-GO Part No. N/A Compression Gauge Adapter, M [B] E-Z-GO Part No. N/A C. Using the starter, turn the engine over with the throttle fully open until the compression gauge stops rising; this is the highest compression reading obtainable. Cylinder Compression Usable Range: 880 ~ kpa (9 ~ 11 kgf/cm², 128 ~ 156 ~ 700 r/min (rpm) Page C-1

2 The following table should be consulted if the obtainable compression reading is not within the usable range. Problem Diagnosis Remedy (Action) Cylinder compression higher than usable range Cylinder compression lower than usable range Carbon accumulation on piston and cylinder head, and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings Incorrect cylinder head gasket thickness Gas leakage around cylinder head Bad condition of valve seating Incorrect valve, piston/cylinder clearance Piston seizure Bad condition of piston ring and/or piston ring grooves Remove the carbon deposits and replace damaged parts if necessary. Replace with a gasket of the proper thickness. Replace damaged gasket and check cylinder head warp. Repair if possible. Adjust. Inspect cylinder and liner and replace/ repair as necessary. Replace. Page C-2

3 Inspect Push Rod Measure Cylinder Head Warp Place the rocker arm push rod on V blocks that are as far apart as possible, and set a dial gauge [A] on the rod at a point halfway between the blocks. Turn the rod to measure the runout. The difference between highest and the lowest dial readings is the amount of runout. B. If the runout exceeds the service limit, replace the rod. Rocker Arm Push Rod Runout Service Limit: TIR 0.5 mm (0.02 in.) Inspect Rocker Arm Lay a straightedge [A] across the lower surface of the head at several different points, and measure warp by inserting a thickness gauge [B] between the straightedge and the head. B. If warp exceeds the service limit, repair the mating surface. Replace the cylinder head if the mating surface is badly damaged. Cylinder Head Warp Service Limit: 0.03 mm (0.001 in.) Clean and inspect the rocker arm where it touches the push rod and valve stem. B. If the contact points [A] are worn or damaged, replace the rocker arm. Page C-3

4 VALVES Inspect Valve Clearance Refer to the Specifications table in Section Adjust Valve Clearance Refer to the Specifications table in Section Inspect Valve Seat Remove the valve. See Remove Valve Mechanism in Section B. The valve stem and guide must be in good condition, or this check will not be valid. G. If the valve seating pattern is not correct, repair the seat. H. Measure the outside diameter [D] of the seating pattern on the valve seat. I. If the outside diameter of the valve seating pattern is too large or too small, repair the seat. Valve Seating Surface Outside Diameter Inlet 32.8 mm (1.29 in.) Exhaust 27.6 mm (1.09 in.) J. Measure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with a vernier caliper. Good [F] Too Wide [G] Too Narrow [H] Uneven [J] K. If the width is too wide, too narrow or uneven, repair the seat (see Repair Valve Seat). Valve Seating Surface Width Standard Inlet 1.1 ~ 1.7 mm (0.043 ~ in.) Exhaust 1.0 ~ 1.5 mm (0.039 ~ in.) Repair Valve Seat Follow the manufacturer s instructions for use of valve seat cutters. Special Tools Valve Seat Cutter, E-Z-GO Part No Check the valve seating surface [A] between the valve [B] and valve seat [C]. C. Coat the valve seat with machinist s dye. D. Push the valve into the guide. E. Rotate the valve against the seat with a lapping tool. F. Pull the valve out, and check the seating pattern on the valve head. It must be the correct width and even all the way around. Valve Seat Cutter, E-Z-GO Part No Valve Seat Cutter, E-Z-GO Part No Valve Seat Cutter, E-Z-GO Part No Valve Seat Cutter Holder, 7 E-Z-GO Part No Valve Seat Cutter Holder Bar E-Z-GO Part No Page C-4

5 If the manufacture s instructions are not available, use the following procedure: Marks Stamped on the Cutter Seat Cutter Operating Cares 1. The valve seat cutter is designed only for valve seat repair. Therefore the cutter must not be used for other purposes. 2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also, use washing oil to wash off ground particles sticking to the cutter. The marks stamped on the back of the cutter [A] represent the following: Cutter angle [B] Outer diameter of cutter [C] Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles. 4. Operating Procedures Clean the seat area carefully. B. Coat the seat with machinist s dye. C. Fit a 45 cutter to the holder and slide it into the valve guide. D. Press down lightly on the handle and turn it right or left. E. Grind the seating surface only until it is smooth. Setting the valve seat cutter holder [A] in position, operate the cutter [B] with one hand [C]. Do not apply too much force to the diamond portion. Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced. F. Measure the outside diameter (O.D.) of the seating surface with a vernier caliper. Prior to grinding, apply oil to the cutter, and during the operation use washing oil to wash off any ground particles sticking to the cutter. 5. After use, wash the cutter with washing oil and apply a thin layer of engine oil before storing. G. If the O.D. of the seating surface is too small, repeat the 45 grind until the diameter is within the specified range. H. If the O.D. of the seating surface is too large, make the 32 grind described below. Page C-5

6 To make the 32 grind, fit a 32 cutter to the holder, and slide it into the valve guide. 1. Grind the seat at a 32 angle until the seat O.D. is within the specified range. 2. Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. Be sure to remove all grinding compound before assembly P. When the engine is assembled, be sure to adjust the valve clearances. The 32 cutter removes material very quickly. 3. Check the seat outside diameter frequently to prevent overgrinding. I. After making the 32 grind, return to the seat O.D. measurement step above. J. Lap the valve to the seat, once the seat width and O.D. are within the ranges specified above. K. Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. L. Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve. M. Repeat the process with a fine grinding compound. [A] Lapping Tool [B] Valve Seat [C] Valve N. The seating area should be marked about in the middle of the valve face. O. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. Page C-6

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8 Measure Valve Spring Free Length Measure Valve Stem Bend Measure the valve spring [A] free length. B. If the free length is less than the service limit, replace the valve spring with a new one. Valve Spring Free Length Standard: 35 mm (1.38 in.) Service Limit: 32.6 mm (1.28 in.) Measure Valve Head Thickness Place the valve in V blocks at each end of the stem, and set a dial gauge [A] on the stem at a point halfway between the blocks. Turn the valve to measure the bend. The difference between the highest and the lowest dial readings is the amount of bend. B. If the valve stem bend is greater than the service limit, replace the valve with a new one. Valve Stem Bend Standard: Less than 0.01 mm ( in.) TIR Service Limit: TIR 0.05 mm ( in.) Measure the thickness [A] of the valve head. B. If the valve head thickness is less than the service limit, replace the valve with a new one. Valve Head Thickness Standard: 0.4 mm (0.016 in.) Service Limit: 0.4 mm (0.016 in.) Page C-8

9 Measure Valve Stem Diameter Measure Valve/Guide Clearance (Wobble Method) Measure the diameter of the valve stem [A] in two directions at right angles, and at four different positions on the stem. B. If any single measurement is less than the service limit, replace the valve with a new one. Valve Stem Diameter Standard: Inlet ~ mm ( ~ in.) Exhaust ~ mm ( ~ in.) Service Limit: Inlet 6.95 mm (0.274 in.) Exhaust 6.93 mm (0.273 in.) Measure Valve Guide Inside Diameter If a small bore gauge is not available, inspect the valve guide wear by measuring the valve/guide clearance with the wobble method, as indicated below. B. Insert a new valve [A] into the guide [B] from the top of the head. C. Set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head upper surface. D. Move the stem back and forth [C] to measure valve/ guide clearance. E. Repeat the measurement in a direction at a right angle to the first. F. If the reading exceeds the service limit, replace the cylinder head. The reading is not actual valve/guide clearance because the measuring point is above the guide. Valve/Guide Clearance (Wobble Method) Measure the inside diameter [A] of the valve guide [B]. B. If the valve guide has worn enough to exceed the service limit, replace the cylinder head. Valve Guide Inside Diameter Standard: ~ mm ( ~ in.) Service Limit: 7.08 mm (0.279 in.) Standard: Inlet 0.06 ~ 0.13 mm ( ~ in.) Exhaust 0.10 ~ 0.17 mm ( ~ in.) Service Limit: Inlet 0.29 mm (0.011 in.) Exhaust 0.33 mm (0.013 in.) Page C-9

10 CAMSHAFT AND TAPPETS Measure Camshaft Bearing/Journal Wear Crankcase Cover Side Camshaft Journal Diameter Standard: ~ mm ( ~ in.) Service Limit: mm (1.966 in.) E. Measure the height of each cam lobe [A]. B. If the cam height is less than the service limit for either lobe, replace the camshaft. Cam Lobe Height Standard: Inlet ~ mm (1.179 ~ in.) Exhaust ~ mm (1.179 ~ in.) Service Limit: Inlet mm (1.176 in.) Exhaust mm (1.176 in.) C. Measure the inside diameter [A] of the camshaft bearing on the crankcase at several points. F. Replace the crankcase if the inside diameter is more than the service limit. Camshaft Bearing Inside Diameter (Crankcase) Standard: ~ mm ( ~ in.) Service Limit: mm ( in.) G. Measure both camshaft journals at several points around the journal circumference. D. If the journal diameter is less than the service limit, replace the camshaft. Crankcase Side Camshaft Journal Diameter Standard: ~ mm ( ~ in.) Service Limit: mm ( in.) Measure the inside diameter [A] of the camshaft bearing on the crankcase cover at several points. H. Replace the crankcase cover if the inside diameter is more than the service limit. Camshaft Bearing Inside Diameter (Crankcase Cover) Standard: ~ mm ( ~ in.) Service Limit: mm (1.972 in.) Page C-10

11 CYLINDER AND PISTONS Clean Piston Remove the piston and piston rings (see Remove Piston in Section A). B. C. Be careful not to widen the ring grooves. Damaged ring grooves will require piston replacement. Never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings. D. Clean the piston ring grooves [A] with a broken piston ring or other suitable tools. Check Piston Ring and Ring Groove Wear Clean the piston (see Clean Piston). Visually inspect the piston rings and ring grooves. Use the scraping tools carefully. Do not gouge the piston head. To avoid gouging, use scrapers that are made of a material that will not cause damage. Scrape the carbon off the piston head with a scraper [A]. B. If the piston rings are worn unevenly or damaged, replace them. C. If the ring grooves are worn unevenly or damaged, replace both the piston and piston rings. D. Measure the clearance between the top and second rings and their grooves using a thickness gauge [A]. Page C-11

12 E. If the piston ring/groove clearance is greater than the specified value, replace the piston. Piston Ring/Groove Clearance Standard: Top, Second 0.04 ~ 0.08 mm (0.002 ~ in.) Service Limit: Top, Second 0.18 mm ( in.) B. Push each ring (one at a time) into the cylinder bore to a point close to the bottom of the cylinder bore. C. Use the piston to push it in to be sure it is square. D. The oil ring is a three-piece assembled ring. It is difficult to measure the ring groove clearance and thickness; visually inspect only. F. Measure the piston ring thickness [A]. G. Use a micrometer to measure at several points around the rings. H. If any of the measurements are less than the service limit, replace the entire set of rings. Piston Ring Thickness Standard: Top, Second 1.47 ~ 1.49 mm ( ~ in.) Service Limit: Top, Second 1.40 mm ( in.) Measure the gap [A] between the ends of the ring [B] with a thickness gauge. E. If the end gap of any ring is greater than the service limit, replace the entire set of rings. Piston Ring End Gap Standard: Top 0.15 ~ 0.40 mm ( ~ in.) Second 0.23 ~ 0.48 mm ( ~ in.) Oil 0.25 ~ 0.75 mm ( ~ in.) Service Limit: Top 0.7 mm (0.03 in.) Second 0.8 mm (0.03 in.) Oil 1.0 mm (0.039 in.) When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston. Measure Piston Ring End Gap Remove the piston rings. Page C-12

13 Measure Piston Pin, Piston Pin Hole, and Connecting Rod Wear F. Remove the piston pin. B. Measure the inside diameter [A] of the small end of the connecting rod at several points. Use a dial bore gauge. Measure the outside diameter of the piston pin with a micrometer at several points. C. If the outside diameter is less than service limit, replace the piston pin. Piston Pin Outside Diameter Standard: ~ mm ( ~ in.) Service Limit: mm ( in.) D. G. If the inside diameter is more than the service limit, replace the connecting rod. Connecting Rod Small End Inside Diameter Standard: ~ mm ( ~ in.) Service Limit: mm ( in.) Measure Piston Diameter Measure the inside diameter [A] of the piston pin hole at several points on both sides. Use a dial bore gauge. E. If the inside diameter is more than the service limit, replace the piston. Piston Pin Hole Inside Diameter Standard: ~ mm ( ~ in.) Service Limit: mm ( in.) Measure the outside diameter [A] of the piston 18 mm (0.71 in.) up [B] from the bottom of the piston at a right angle to the direction of the piston pin hole. B. If the measurement is less than the service limit, replace the piston. Piston Diameter Standard: ~ mm ( ~ in.) Service Limit: mm (3.220 in.) Page C-13

14 Check Cylinder Inside Diameter Clean and measure the cylinder inside diameter. B. Use a dial bore gauge to measure front-to-back and side-to-side at the points as shown in the figure. C. If any of the cylinder bore measurements is greater than the service limit, replace the crankcase. 10 mm (0.39 in.) [A] 35 mm (1.38 in.) [B] Cylinder Inside Diameter Standard: ~ mm (3.227 ~ in.) Service Limit: mm (3.232 in.) Cylinder Bore Out-Round Service Limit: 0.05 mm (0.002 in.) CRANKSHAFT AND CONNECTING RODS Clean/Inspect After removing, clean the crankshaft and connecting rods with a high-flash point solvent and dry them with compressed air. B. Inspect the teeth of the crankshaft gear for pitting, fatigue cracks, burrs and evidence of improper tooth contact. C. Replace the gear if necessary. D. Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear, scratches, evidence of improper contact or other damages. E. Replace them if necessary. Measure Connecting Rod Bend/Twist Measure connecting rod bend. B. Select an arbor of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end. C. Select an arbor of the same diameter as the piston pin and at least 100 mm long, and insert the arbor through the connecting rod small end. D. On a surface plate, set the big-end arbor on V blocks [A]. E. With the connecting rod held vertically, use a height gauge [B] to measure the difference in the height of the small end arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend. F. If connecting rod bend exceeds the service limit, the connecting rod must be replaced. Connecting Rod Bend Service Limit: 0.15/100 mm (0.006/3.94 in.) Page C-14

15 G. Measure connecting rod twist. H. C. Measure the crankpin width [A] with a dial caliper. With the big-end arbor still on the V blocks [A], hold the connecting rod horizontally. Use a height gauge [B] to measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist. I. If connecting rod twist exceeds the service limit, the connecting rod must be replaced. Connecting Rod Twist Service Limit: 0.15/100 mm (0.006/3.94 in.) Measure Connecting Rod Big End/Crankpin Width Wear D. If the crankpin width is more than the service limit, replace the crankshaft. Crankpin Width Standard: 28.0 ~ 28.2 mm (1.10 ~ 1.11 in.) Service Limit: 28.4 mm (1.12 in.) Measure Connecting Rod Big End Bearing/ Crankpin Wear Apply a thin film of oil on the thread of the cap bolts. B. Install the cap bolts and tighten the bolts to the specified torque (see Install Piston in Section D). C. Measure the connecting rod big end width [A] with a micrometer or dial caliper. B. If the measurement is less than the service limit, replace the connecting rod. Connecting Rod Big End Width Standard: 27.4 ~ 27.7 mm (1.08 ~ 1.09 in.) Service Limit: 27.0 mm (1.06 in.) Measure the inside diameter [A] of big end at several points with a telescoping gauge or inside micrometer. D. If the inside diameter is more than the service limit, replace the connecting rod with a new one. Connecting Rod Big End Inside Diameter Standard: ~ mm ( ~ in.) Service Limit: mm (1.694 in.) Page C-15

16 E. Measure Crankshaft Main Bearing/Journal Wear Measure the crankpin outside diameter [A]. F. Use a micrometer to measure several points around the crankpin circumference. G. If the crankpin diameter is less than the service limit, replace the crankshaft with a new one. Crankpin Outside Diameter Standard: ~ mm ( ~ in.) Service Limit: mm (1.691 in.) Measure Crankshaft Runout Measure the crankshaft runout. B. Measure the diameter [A] of the crankshaft main journal. B. If the journal has worn enough to exceed the service limit, replace the crankshaft with a new one. Crankcase Side Crankshaft Main Journal Diameter Standard: ~ mm ( ~ in.) Service Limit: mm (1.375 in.) C. Set the crankshaft in a flywheel alignment jig [A] or on V blocks gauge. C. Set a dial gauge [B] against both bearing journals. D. Turn the crankshaft slowly to measure the runout. The difference between the highest and lowest dial gauge readings (TIR) is the amount of runout. E. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm ( in.) or less Service Limit: TIR 0.05 mm (0.002 in.) Measure the inside diameter [A] of the crankshaft main bearing (crankcase side). D. If the bearing has worn enough to exceed the service limit, replace the crankcase with a new one. Crankshaft Main Bearing Inside Diameter (Crankcase Side) Standard: ~ mm ( ~ in.) Service Limit: mm (1.380 in.) Page C-16

17 BALANCER SHAFT E. Measure Balancer Shaft Bearing/Journal Wear Measure both balancer shaft journal diameters [A] at several points around the journal s circumference. B. If journal diameter is less than the service limit, replace the balancer shaft with a new one. Balancer Shaft Journal Diameter Standard: ~ mm ( ~ in.) Service Limit: mm ( in.) C. Measure the inside diameter [A] of the balancer shaft bearing on the crankcase cover at several points. F. If inside diameter is more than the service limit, replace the crankcase cover with a new one. Balancer Shaft Bearing Inside Diameter (Crankcase cover) Standard: ~ mm ( ~ in.) Service Limit: mm (1.262 in.) BREATHER VALVE Inspect Breather Valve Remove the breather valve (see Remove Breather Valve). B. Inspect the reed valve for breakage, hair cracks or distortion; replace it if necessary. C. Inspect the back plate for damage or rough contact surface; replace it if necessary. D. Inspect the valve seating surface. The surface should be free of nicks or burrs. E. Align center of the valve seat with center of the reed valve and back plate, then tighten the breather valve screw. Measure the inside diameter [A] of the balancer shaft bearing on the crankcase at several points. D. If inside diameter is more than the service limit, replace the crankcase with a new one. Balancer Shaft Bearing Inside Diameter (Crankcase) Standard: ~ mm ( ~ in.) Service Limit: mm (1.262 in.) Page C-17

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