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HARLEY-DAVIDSON V-ROD BIG BORE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-10-2010

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The cylinder sleeves provided with the Wiseco V-Rod big bore kit have been finished honed to size and the piston to cylinder clearance has been set. Prior to installation, the sleeves must be washed in hot soapy water (not parts washer solvent) and dried. Coat the bore surface with motor oil and wipe it with a white towel. If the towel shows any remaining grit, repeat the hot soapy water washing process until the towel will only show clean motor oil. CAUTION: Test fit the cleaned sleeve (without O-Rings installed) into the engine block. Sleeve should drop into position. If sleeve will not easily drop into position, warm the engine block with a hair dryer until sleeve will drop into position. Remove sleeve, then continue installation procedures. From the bottom side of the sleeve, gently roll the 2-cylinder sleeve O-rings into the two grooves on each sleeve. Apply motor oil to the O-rings and gently install the sleeves into the block until bottomed. CAUTION: DO NOT ATTEMPT TO INSTALL SLEEVES WITHOUT LUBRICATING THE O-RINGS. FAILURE TO LUBRICATE O-RINGS COULD RESULT IN TORN OR DAMAGED O-RINGS THAT WOULD NOT BE EVIDENT UNTIL ENGINE WAS STARTED. INCORRECTLY INSTALLED O-RINGS CAN RESULT IN CATASTROPHIC ENGINE DAMAGE. NOTE: REFER TO THE OEM SERVICE MANUAL FOR ALL TORQUE SPECIFICATIONS PISTON RING PREPARATION Wiseco V-Rod pistons incorporate an advanced 2 ring system • The top ring is file-fit, and as such, requires that the end gap must be clearanced. The proper end gap clearance is .016-.018″ with the ring installed squarely in the bore. The top ring must be installed on the piston with the dot marking toward the top of the piston. • The oil ring is comprised of the expander and two rails. Install the expander first, and then the rails. Check to make sure the expander tips have not overlapped. It is not necessary to clearance the end gaps on the oil rails. The rails should be installed without modification. PISTON INSTALLATION The Wiseco V-Rod big bore kit is supplied with pistons that are front and rear cylinder specific. Install the front piston 4792M10795 in the front cylinder with the arrow facing the front of the engine. Install the rear piston 4793M10795 in the rear cylinder with the arrow facing the front of the engine. A piston ring compressor is required to install the pistons into the cylinders. Front of engine ➔ 4792M10795 ( Front piston) 4793M10795 ( Rear piston) FWD 4793M10795 FWD 4792M10795 For further information call the Wiseco Tech Line:

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Harley-Davidson Big Twin Evolution and Twin Cam Edelbrock/ JE Sport INSTALLATION INSTRUCTIONSsman Pistons

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION PROCEDURE Note: All Evolution® “Big Twin” pistons are marked “Front” or “Rear” and come with rings, wrist pins, and locks. • Note: We highly recommend that a dealer or trained mechanic perform the installation of these pistons. Specialized equipment is required for honing and finishing the cylinders to ensure long life of the piston and cylinder assembly. 1. Remove original equipment cylinders from engine. Refer to a shop manual or other reference book for specific steps, if needed. (Note: Care should be taken not to bend the studs or damage the cylinder during removal of the cylinders.) 2. With a small screwdriver, move the wrist pin retainer around to gain access to the tail of the retainer as it lines up with the notch in the bottom of the wrist pin hole. 3. Use a small screwdriver, pick or awl to roll the wrist pin retainer out of its groove. 4. Push wrist pin out and remove piston. 5. Repeat procedure for the other piston. 6. At this point, take cylinders, new pistons, and piston-to-wall clearance specifications to your dealer or machine shop to perform necessary machining operations. • IMPORTANT NOTE (Evolution® and Twin Cam®): The cylinder bore must be machined/honed to provide .0025″ of piston-to-wall clearance. Measure the piston diameter at a point .500″ up from the lower skirt (See Figure 3). 7. Starting with the front cylinder, install new piston rings and one wrist pin retaining clip (Note: Second ring has a dot which must face up when the ring is installed) . 8. Place the piston over the conecting rod, making sure that the intake valve pocket is towards the intake side. (For Evolution ® , see Figure 1. For Twin Cam ® , see Figure 2) . Coat the wrist pin with engine oil and insert it into the piston. Install the second wrist pin retainer into the groove. 9. Lightly coat the piston skirt with engine oil. Place a piston ring compressor over the piston/ring assembly and compress. Place the cylinder over the piston and gently push down until all rings are in the cylinder. Remove the ring compressor, and push the cylinder the rest of the way down. (Note: Be careful not to get oil onto the base gasket.) 10. Place two nuts and washers on opposite corners of the #1 cylinder to hold it down while you repeat the procedure for cylinder #2. 11. Assemble the rest of the engine per factory specifications. Start the engine and let it run at 2000 rpm for about 10 minutes.

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KTM 250 SX-F & XC-F Piston Kits Installation and Removal Manual

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Filed Under (KTM) by admin on 28-01-2012

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Features* Benefits •*Dedicated*forging •*Light*weight,*superior*strength,*optimized*design •*Stock*Compression •*Matches*OEM*compression*ratio •*Dome*design Improved*flame*travel*to*maximize*air/*fuel*burn*efficiency •*Chrome*plated*piston*pin •*Reduced*friction,*improved*scuff*resistance •*Horizontal*slot*pin*oiling .•*Improved*lubrication,*better*pin*oiling,*reduced*friction •*Pressure*seal*groove •*Maximum*ring*seal •*Skirt*coated •*Reduced*friction,*quieter*operation,*improved*scuff*resistance •*Dedicated*rings ……………………………… •*Optimized*for*each*application,*light*weight,*high*perfromance,*better*oil*control •*Experience ……………………………………. •*68*years*as*the*industry*leader*in*forged*piston*technology Piston sold complete*with:*Rings,*piston*pin,*and*circlips. Complete*top*end*kits*sold*complete*with:*Piston,*rings,*piston*pin,*circlips,*and*complete*top*end*gasket*kit

S&S Super Stock Cylinder Head Kit Installation Instructions for 1984 And Later Evolution Big Twin and Sportster Engines

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Filed Under (Harley Davidson) by admin on 28-11-2010

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check Piston Alignment in Cylinder Bore The purpose of this procedure is to check for and correct possible piston misalignment in the cylinder bore. During normal manufacturing, engine components such as crankcases, cylinders, and connecting rods can be machined to dimensions within factory specifications but on the extreme ends of the tolerance range. Sometimes these components when combined together form an assembly that is borderline or actually “out of print”. The worst result is that the pistons can run cocked in the cylinder bores causing the connecting rods to thrust to the sides exerting unnecessary stress on the pistons, rings, rod bearings and other related parts. This procedure is not the same as “blue printing”, but it provides almost the same result. We feel that not enough emphasis is given to checking the piston alignment in the cylinder bore. NOTE – All engines should be checked upon disassembly. This applies to any engine receiving new pistons which includes those being completely overhauled. CAUTION – Pistons which do not run true in cylinder bores may cause excessive connecting rod side thrusting. This may lead to premature ring, piston, connecting rod and rod bearing wear and eventual failure of these parts. Visual Procedure A. Reinstall cylinders on old pistons without rings. Hold cylinders securely in place. B. Move piston tight toward camside of engine. C. Turn engine over in normal direction of travel 2 or 3 revolutions and observe piston during process. D. Move piston toward driveside of engine and repeat Step C. If misalignment exists, piston will appear closer to cylinder wall at one point around circumference. Condition can be corrected by bending rod in opposite direction. Figure 1 shows an exaggerated side view. E. Repeat Steps B to D for other cylinder. F. Remove pistons and cylinders. Observe pistons for wear spots on sides above top compression ring. If either side near wristpin is worn clean while side opposite is carboned up, then piston was not running straight and true in cylinder bore. Piston will also generally show diagonal wear pattern on thrust faces of skirts and possibly signs of connecting rod to wristpin boss contact inside piston.

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BMW PISTONS AND RINGS INSTALLATION INSTRUCTIONS

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Filed Under (BMW) by admin on 26-10-2010

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1. Always clean the grooves before installing rings. Carbon build-up in the groove will lead to ring “bottoming” and can result in engine seizure. 2. Check the fit of rings in the groove. A maximum of .003″ side clearance is allowable. 3. Check the cylinders for taper and out-of-roundness. Any taper of out-of-roundness will have an adverse effect on the performance of an engine. Excessive piston clearance will detract from maximum performance as well. 4. Allow ample ring gap. There is far more danger of ring butting than of an appreciable compression loss through the ring gap. Gaps, if staggered, do not cause any measurable reduction of compression. Compression rings should be fitted with a minimum of .004″ end gap per inch of cylinder deglazing. 5. Always deglaze cylinder walls before installing new rings. A 400 grit stone is recommended for deglazing. 6. All parts should be spotlessly clean before installation. Dirt in any form is the worst enemy of a hi- performance engine. You may wash all parts in hot, soapy water. Ring Gap Installation 1. Do not gap oil control rings. Start with the oil control expander. Expander Ring ends butt together. Do not overlap them. 2. Install oil control rings. Set gap 90 from where expander ring butts together. Gap top oil control ring 180 from lower oil control ring gap. 3. Install 2nd and top ring also with marks up. Stagger gaps

HARLEY DAVIDSON XLH 1200cc BIG BORE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Boring and Honing Procedures 1. Check again for burrs on cylinder gasket surfaces and remove burrs before performing Step 2. 2. Install original head and base gaskets, CYLINDER TORQUE PLATES (Part Number 33446-A) and TORQUE BOLTS (Part Number 33446-4). Tighten TORQUE BOLTS following tightening procedure given in the INSTALLATION, CYLINDER HEAD procedure in the ENGINE section of the Service Manual. NOTE Torque plates, properly tightened and installed with gaskets, simulate engine operating conditions. Measurements will vary as much as 0.001 inch without torque plate. 3. The cylinder must be bored with gaskets and torque plates attached. Bore the cylinder to 0.003 inch under the desired finish size. 1 WARNING CAUTION CAUTION 1 WARNING Kit Number 4. Hone the cylinder to its finished size (See Figure 1) using a 280 grit rigid hone followed by a 240 grit flexible ball hone. Honing must be done with torque plates attached. All honing must be done from the bottom (crankcase) end of the cylinder. Work for a 60 degree crosshatch pattern. 5. See Figure 1. After machining and honing, chamfer the bottom edge of the cylinder liner. the chamfer provides a beveled surface for easier installation of the cylinder over the piston rings. Break leading edge of liner to a flat surface. The bottom edge of the liner will be somewhat sharp after machining. This sharp edge could easily be damaged during installation of the cylinder. Piston Installation The 1200cc pistons have an arrow on the top of the piston. This arrow must face the front of the engine when piston is installed. There is no front cylinder piston or rear cylinder piston. New pistons can be installed in either cylinder. Check piston rings for proper side clearance and end gap (See XLH Service Manual). Be sure end gaps of adjacent rings are installed 90 degrees apart. Assembly Follow assembly and torque specifications given in the ENGINE section of the applicable Service Manual. Replace original gaskets, O-rings and seals with new components furnished in kit. NOTE Push rod covers on 1991 and later models are one-piece and the correct O-rings are as follows: Bottom – Part Number 17944-89 Upper – Part Number 11190 Engine Break In For the first 500 miles, to wear-in critical parts, observe these few simple driving rules: During the first 50 miles, keep the engine speed below 2500 RPM in any gear. Up to 500 miles, vary the engine speed, avoiding any steady speed for long distances. Engine speed up to 3000 RPM is permissible in any gear. Avoid fast starts at wide open throttle. Drive slowly until engine warms up. Avoid running the engine at extremely low RPM in higher gears. 2 of 3 -J00001 1200cc CYLINDER FINAL BORE SIZE AFTER HONING STANDARD BORE DIAMETER 3.4980 inch + 0.0002 inch Figure 1. Bottom Edge of Cylinder Liner Chamfer i04852 Break Edge to Flat Surface

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HONDA CB 90O C CYLINDER HEAD PISTON REMOVAL and INSTALLATION

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Filed Under (Honda) by admin on 05-12-2011

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108 CYLINDER/PISTON PISTON/PISTON RING INSPEC- TION I Inspect the piston ring-to-groove clearance. NOTE Mark the rings so that they can be returned to their original locations. Inspect the pistons for damage and cracks; ring grooves for wear. Insert each piston ring into the cylinder, and inspect the end gap

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Lilac LS-18 Motorcycle Maintenance Standards

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Filed Under (Lilac) by admin on 25-11-2010

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CYLINDER AND CYLINDER HEAD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Cylinder Bore 54 -0.01 54.1 Boring After boring honing should be performed Ovality 0.01 0.05 Boring After boring honing should be performed Taper 0.01 0.05 Boring After boring honing should be performed Oversize 0.25 steps 55 max. Do R and L cylinders at same time / 4 steps Valve Seat Width 0.8 – 1.0 1.3 Adjust Use a cutter Angle 45∞ Combustion Chamber Volume 18.2cc -0.5cc Remove carbon if heavy accumulation Compression Ratio 7.8:1 Head Gasket Thickness 1.0 Cylinder Head Nut Torque 3.0 kg/m (22 ft.-lb.) Out standard Adjust 8mm nut Intake and Exhaust Ports Port Wall SurfaceMust be smooth Remove carbon Intake and Exh. Valve GuidesOD 12 +0.09 +0.1 ID 7 +0.01 -0.0 7.06 Exchange Intake Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Exhaust Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Intake and Exhaust Valve Seat Face Width Range 0.8~1.0 1.3 Use valve seat cutter Intake Valve Guide Clearance 0.02~0.04 0.08 Replace valve or guide Exhaust Valve Guide Clearance 0.06~0.08 0.12 Replace valve or guide Valve Spring (Large) Installed Load 10.2 kg 8.7 kg Replace Fitted length 31.5 Free Length 36.5 34.7 Replace Tilt 1.5/100 3/100 Replace Valve Spring (Small) Installed Load 5.48 kg 4.65 kg Replace Fitted length 29.5 Page 4 of 10 Free Length 33.5 31.8 Replace Tilt 1.5/100 3/100 Replace Rocker Arm ID 12 +0.00 +0.02112.07 Replace Rocker Shaft OD 12 -0.06 -0.024 11.92 Replace Arm and Shaft Clearance 0.045~0.006 0.10 Replace arm or shaft Tappet Clearance 0.05 Out standard Adjust Measure cold at TDC Rocker Arm Ball Surface 1.8îR -0.006 -0.024 Replace if severe wear Pushrod Bend 0.1 0.5 Straighten Over 100mm (2) CRANKSHAFT, PISTON AND CONROD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Piston OD @ Top 53.65 -0.02 Max Diameter 53.95 -0.015 53.85 Replace Ovality 0.1 Piston and Cylinder Clearance 0.04~0.05 0.15 Replace Piston Ring Groove Clearance 0.03~0.07 0.10 Replace Piston Oversize Step 0.25 4 steps Top Ring and 2nd Ring Thickness 2 -0.01 -0.03 1.92 Replace Width 2.5 -0.01 0.55kg Tension 0.85 – 1.15kg 1 Replace End Gap 0.15 – 0.35 Replace Oil Ring Thickness 3.2 -0.01 -0.03 3.12 Replace Width 2.5 -0.1 Tension 1.0~1.3kg 0.65kg Replace End Gap 0.15~0.35 1 Replace Ring Gap Position 120∞ 3 equal spacesOut standard Adjust Avoid Piston Pin Axis Ring Oversizes 0.25 steps 4 steps Piston Pin OD 15 -0.0 +0.006 14.95 Replace Pin Hole in Piston ID 15 +0.012 -0.015.05 Replace Pin and Piston Clearance -0.006 ~ +0.012 0.06 Replace Hand push fit piston at 100∞C Conrod Small End Bush ID 15+0.027+0.016 15.07 Replace bush Conrod and Piston Pin Clearance 0.01~0.027 0.07 Replace Crankpin OD 24.94 +0.0+0.0124.90 Replace Crankpin Roller OD 5 (+0.001+0.003) Refer to conrod ID Replace 3Sizes; 52 per assembly for selective fit 5 (+0.0 -0.002) 5 (-0.003 -0.005) Conrod ID 34.95+0.03+0.02435.02 Axial Play 0.2~0.4 0.5 Adjust Radial Play 0.026~0.036 0.06 Replace

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TRIUMPH 750 BIG BORE CYLINDER AND PISTON SET FOR 650 TWINS INSTALLATION

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Filed Under (Triumph) by admin on 29-10-2010

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Step 1. Unpack your big bore kit and inspect the contents. There should be the following: 1. Cylinder x l 2. piston with wristpin x 2 3. Hepolite piston ring set x l 4. Special big bore head gasket Step 2. Thoroughly wash the cylinder bores with soap and water. Do not use solvent! Dry bores with air or a lint free towel and let completely air dry. This step is most important and will greatly extend the life of the pistons. Step 3. Following the procedure outlined in your service manual, drain the fuel tank, remove the exhaust system, fuel tank and carburetors. Have a catch basin handy to capture any fuel that may spill from the carburetors, as fuel is highly flammable and can be ignited by a dryer pilot light etc. from a long distance. Clean up any spilled fuel immediately and dispose of away from any source of ignition. Store the fuel tank in a well vented area, outdoors is best, in the event your fuel taps should leak. Step 4. Remove the rocker boxes by slacking the 9 head bolts a little at a time in a star pattern. Remove the 6 nuts at the front and back of the head. Remove the 4 corner rocker box bolts. Remove the head bolts and rocker boxes. Remove the push rods. Examine the push rods to insure they are straight and the ends are tight. Replace any suspect push rod. Step 5. Remove the cylinder head. Now would be a good time for guide and valve renewal. This is best left to an expert. More cylinder heads have been ruined by auto machine shops than by hard use. If you do not have a qualified shop in your area please call for a referral. Step 6. Remove the push rod tubes and the cylinder base nuts. Clip rubber bands around the top of the lifters to keep them from dropping into the crankcase. Have a few lint free rags handy. Bring the pistons to the top of the stroke and begin lifting off the cylinder. If the cylinder is hard to lift off, thread a nut on one of the base studs and use a tire lever to pry against the bottom fin close to its base using the stud as a fulcrum. After partially raising the cylinder stuff the crankcase mouth with rags to keep any carbon or broken rings from entering the crankcase. These will remain in place until step 12. Step 7. Leaving the rags in the crankcase remove the wrist pin circlips from the pistons and discard. Heat the piston and gently push the wrist pin out. Do not use force as this can damage the connecting rod or its bearings. Be sure to account for all the clips as one left in the crankcase can do extensive damage. Step 8. Clean all gasket surfaces to remove any traces of the old gaskets. Use Pennatex gasket remover if needed. Be very careful not to scratch the gasket surface or to allow any gasket particles to enter the crankcase. Even a small bit of gasket can stop the oil pump from working! Step 9. Note the direction and location of the lifters. These must be replaced in the same position as when removed. Remove the lifter blocks from the old cylinder. Start by removing the small retaining bolts and washers. The lifter blocks are extremely fragile and are easily broken. They are also very expensive so great care must be taken in this step! Triumph special tool 222-616008 is advisable here. Apply pressure to the center of the block only. Do not press against the tangs that locate the lifter! A tool can be fabricated using two dowels to locate in the lifter holes. Step 10. Clean and examine the lifters and camshaft faces. Clean the lifter blocks and remove the sealing oring under the locating flange. Replace these with the new orings in the gasket set. Apply a smear of gasket sealant to the lifter block oring and press into the new cylinder. Be sure the lifter block is parallel with the bores and the grooved block is on the exhaust side. Apply a small amount of assembly oil to the lifters and replace in the exact position they came from

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2009 KTM 250 SX-F & XC-F Piston Kits REMOVAL, INSTALLATION

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Filed Under (KTM) by admin on 02-02-2012

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Features* Benefits •*Dedicated*forging ………………………….. •*Light*weight,*superior*strength,*optimized*design •*Stock*Compression ………………………… •*Matches*OEM*compression*ratio •*Dome*design …………………………………. •*Improved*flame*travel*to*maximize*air/*fuel*burn*efficiency •*Chrome*plated*piston*pin ……………….. •*Reduced*friction,*improved*scuff*resistance •*Horizontal*slot*pin*oiling …………………. •*Improved*lubrication,*better*pin*oiling,*reduced*friction •*Pressure*seal*groove ………………………. •*Maximum*ring*seal •*Skirt*coated …………………………………… •*Reduced*friction,*quieter*operation,*improved*scuff*resistance •*Dedicated*rings ……………………………… *Optimized*for*each*application,*light*weight,*high*perfromance,*better*oil*control •*Experience ……………………………………. •*68*years*as*the*industry*leader*in*forged*piston*technology

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