Buell 2002 X1, Service Manual

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2002 Buell X1: Engine 3-25
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Measuring Cylinder Bore
1. Remove any burrs from the cylinder gasket surfaces.
2. See Figure 3-34. Install a head and base gasket, and
CYLINDER TORQUE PLATES (Part No. HD-33446A)
and XL EVOLUTION TORQUE PLATE BOLTS (Part No.
HD-33446-86). Tighten the bolts using the same method
used when installing the cylinder head screws. See
3.5
CYLINDER HEAD .
NOTE
Torque plates, properly tightened and installed with gaskets,
simulate engine operating conditions. Measurements will
vary as much as 0.001 in. (0.025 mm) without torque plates.
3. Take cylinder bore measurement in ring path, starting
about 1/2 in. (12.7 mm) from top of cylinder, measuring
from front to rear and then side to side. Record readings.
4. Repeat measurement at center and then at bottom of
ring path. Record readings. This process will determine if
cylinder is out-of-round (or “egged”) and will also show
any cylinder taper or bulge.
5. See Table 3-7. If cylinder is not scuffed or scored and is
within service limit, see 3.6 CYLINDER AND PISTON on
page 3-25 .
NOTE
If piston clearance exceeds service limit, cylinders should be
rebored and/or honed to next standard oversize, and refitted
with the corresponding piston and rings. Do not fit piston
tighter than 0.0007 in. (0.0178 mm). See
3.1 SPECIFICA-
TIONS .
Measuring Piston
Because of their complex shape, the pistons cannot be accu-
rately measured with standard measuring instruments.
The pistons have the typical elliptical shape when viewed
from the top. However, they also are barrel-shaped when
viewed from the side. This barrel shape is not symmetrical.
Any damage to the piston will change its shape, which will
lead to problems.
Fitting Cylinder to Piston
Since pistons cannot be accurately measured with standard
measuring instruments, the bore sizes must be observed.
Bore sizes are listed in
Table 3-8. Example: A 0.005 in.
(0.127 mm) oversize piston will have the proper clearance
with a bore size of 3.502 in. ± 0.0002 in. (88.951 mm ±
0.0051 mm) for the 1200cc engine.
Figure 3-34. Measuring Cylinder Bore Using Torque
Plates (Part No. HD-33446A)
Table 3-7. Cylinder Bore
Service Wear Limits
BORE SIZES IN. MM
Standard Bore 3.5008 88.9203
0.005 in. OS bore
(0.127 mm)
3.5050 89.0270
0.010 in. OS bore
(0.254 mm)
3.5100 89.1540
0.020 in. OS bore
(0.508 mm)
3.5200 89.4080
0.030 in. OS bore
(0.762 mm)
3.5300 89.6620
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