WM, Workshop Manual, K650, K700, K950, K1250, 2001-06, Power ...
WM, Workshop Manual, K650, K700, K950, K1250, 2001-06, Power ...
WM, Workshop Manual, K650, K700, K950, K1250, 2001-06, Power ...
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Cylinder and piston<br />
5<br />
Service tips<br />
Defect:<br />
Broken cooling fins, damaged threads or broken screw at<br />
exhaust port.<br />
Seizure marks in the cylinder bore (especially at the exhaust<br />
port).<br />
The surface lining in the cylinder bore is worn (primarily at<br />
the head of the cylinder).<br />
The piston displays seizure scratches.<br />
The piston ring is stucked in its groove.<br />
Procedure:<br />
In severe cases - replace the cylinder.<br />
Repair the thread with Heli-Coil.<br />
Rub the damaged part with fine emery cloth to remove<br />
adhered aluminium.<br />
With deeper seizure scratches the cylinder and piston should<br />
be replaced.<br />
Replace cylinder and piston.<br />
Rub the damaged part carefully with a fine file or emery cloth.<br />
Before the piston is fitted the cylinder should be rubbed as<br />
above. With deeper scratches the piston and where necessary<br />
also the cylinder should be replaced.<br />
Carefully loosen the piston ring and clean the groove very<br />
carefully before assembly. Check the wear on the piston ring<br />
by placing it in the lower part of the cylinder.<br />
Wear tolerances<br />
Cylinder bore<br />
Piston ring gap<br />
Piston ring groove<br />
Piston ring play<br />
The surface finish is worn away<br />
revealing the aluminium.<br />
Max. 1.0 mm (0.04") with the piston<br />
ring pushed into the lower part of<br />
the cylinder.<br />
Max. 1.6 mm (0.<strong>06</strong>"). Clean the<br />
groove carefully before checking the<br />
mea-surement.<br />
Max. 0.15 mm (0.0<strong>06</strong>"). Clean the<br />
groove carefully before checking<br />
the mea-surement.<br />
Assembly<br />
All models<br />
Fit the piston on the connecting rod.<br />
Make sure that the arrow on the piston top<br />
is turned to the exhaust port.<br />
505 38 17-05<br />
Assembly<br />
All models<br />
Before fitting the piston and cylinder see<br />
the section ”Cleaning, inspection” and<br />
”Analysis and procedures”.<br />
Lubricate the piston bolt’s needle bearing<br />
with a few drops of engine oil.<br />
Align the arrow on the piston top with the<br />
exhaust port.<br />
Press in the piston bolt by means of the<br />
mandrel 505 38 17-05 and fit the circlips<br />
by means of a pair of flat pliers. Check<br />
that they sit correctly in their grooves by<br />
turning them with the pliers.<br />
55
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