717 Engines

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Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) INSPECTION 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, connecting rods should be checked for straightness and crankshaft for deflection/misalignment. Refer to BOTTOM END for procedures. Inspect plane surfaces for warpage. Small deformation 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. The inspection of engine top end should include the following measurements. ENGINE MEASUREMENT Cylinder taper N.A. Cylinder out of round N.A. Piston/cylinder wall clearance 717 engine Piston/cylinder wall clearance 787 RFI engine Piston/cylinder wall clearance 947 DI engine Ring/piston groove clearance 717 engine Ring/piston groove clearance 787 RFI engine Ring/piston groove clearance 947 DI engine Ring end gap 717 engine Ring end gap 787 RFI engine Ring end gap 947 DI engine N.A.: NOT APPLICABLE TOLERANCES NEW PARTS (min.) (max.) 0.10 mm (.0039 in) 0.13 mm (.005 in) 0.12 mm (.0047 in) 0.025 mm (.001 in) 0.025 mm (.001 in) 0.044 mm (.002 in) 0.25 mm (.010 in) 0.40 mm (.016 in) 0.55 mm (.022 in) 0.05 mm (.002 in) 0.008 mm (.0003 in) N.A. N.A N.A. 0.070 mm (.0027 in) 0.070 mm (.0027 in) 0.089 mm (.003 in) 0.40 mm (.016 in) 0.55 mm (.022 in) 0.7 mm (.028 in) WEAR LIMIT 0.1 mm (.004 in) 0.08 mm (.003 in) 0.20 mm (.008 in) 0.24 mm (.009 in) 0.20 mm (.008 in) 0.20 mm (.008 in) 0.24 mm (.009 in) 0.20 mm (.008 in) 1.0 mm (.039 in) 1.0 mm (.039 in) 1.1 mm (.043 in) NOTE: Replacement cylinder sleeves are available if necessary. Also, oversize pistons of 0.25 mm (.010 in) are available for all engines and oversize pistons of 0.5 mm (.020 in) are available for the 717 engine. Cylinder Taper Using a cylinder bore gauge, measure cylinder diameter at 16 mm (5/8 in) from top of cylinder just below auxiliary transfer port, facing exhaust port and just below the auxiliary transfer port facing the exhaust port. Compare readings. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced. 112 smr2004-Complete Line Up 14
A F01D8AA 2 1. Measuring perpendicularly (90°) topistonpinaxis 2. Auxiliary transfer port A. 16 mm (5/8 in) 1 Cylinder Out of Round Using a cylinder bore gauge, measure cylinder diameter at 16 mm (5/8 in) from top of cylinder. Measure diameter in piston pin axis direction then perpendicularly (90°) to it. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced. F01D8BA Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) A 1. Measuringinpistonpinaxis 2. Measuring perpendicularly (90°) to piston pin axis A. 16 mm (5/8 in) 1 USED PISTON MEASUREMENT Note the measurement on the piston dome. F00D0EA 2 1 1. Piston dome 2. Piston measurement Using a micrometer, measure piston skirt perpendicularly (90°) to piston pin according to the following table. ENGINE TYPE MAXIMUM “A” mm (in) 717 29 (1.142) smr2004-Complete Line Up 113 15 A 2
Page 1 and 2: TOP END 717 Engines Molykote 111 F1
Page 3 and 4: 947 DI Engines 26 10 N•m (89 lbf
Page 5 and 6: 2 3 1 F06D16B RAVE VALVE CLOSED 1.
Page 7 and 8: F06D0QA 1 1. Remove screws Remove R
Page 9 and 10: F06D28A 1. Remove O-ring 1 Remove s
Page 11 and 12: Remove cylinder head no. 2. If shel
Page 13: F00B0KA 1 1. Tool cut-out toward bo
Page 17 and 18: F00B09A 2 1. Use the micrometer to
Page 19 and 20: F01D8KA 1 3 2 1. Sliding valve 2. O
Page 21 and 22: - Replace the inner halves by the a
Page 23 and 24: 947 DI Engines Securecirclipinpisto
Page 25 and 26: F01D45A 717 ENGINES 1. Aligning cyl
Page 27 and 28: Apply Molykote 111 on threads of cy
Page 29 and 30: Compare the obtained value with the
Page 31 and 32: Section 04 ENGINE (2-STROKE) Subsec

717 Engines

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