Pre-Assembly
•
Thoroughly clean and inspect parts prior to assembly for damage and compatibility
•
•
Crank & Rod Prep:
Check the crank journals for any nicks or scratches
and remove them with a fine stone to prevent damage to the bearing seat
areas. Check the rod bolt holes to be sure the bolts seat properly and burr or
lap mating edges of connecting rod insert bearing to insure proper clearance.
•
•
Cam Prep:
Inspect the cam gear and lobes for burrs. If necessary, deburr
& polish these areas. Thoroughly clean the cam to remove scale or blasting
media left from the heat-
treating process.
Lapping the Block:
Lap the
cylinder head and motor
mount surfaces on a surface
plate to remove any burrs or
irregularities. This will insure
proper sealing for the head
and also keep from binding
the crank when the engine is
attached to the motor mount.
•
•
Fitting the Piston:
Remove
all sharp edges from piston
with a deburring wheel or fine
sand paper. Hone the block
using a 280/400 grit stone to achieve .0035 - .0055” piston to cylinder
clearance (measure the piston 90° from the wrist pin and ¼” from the
bottom). Finish the bore with a plateau hone using about 15/20 strokes. After
the piston has been fitted clean the block with hot soapy water and spray the
bore and bearing with WD-40 to prevent rust.
•
•
Setting the Ring Gap:
Note it is very
important to follow the manufacturers
recommended ring gap settings. Running
too tight of a gap on the top and second
rings will result in cylinder damage and
cutting the expander on the oil ring will result in a loss in oil control. We have
run the top 2 rings at .010+ gap and the oil rings as supplied for a full season
with excellent results.
(
See piston ring instructions supplied with piston)
Summary of Contents for YF200 R1
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