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汽缸及活塞

Cylinder and Piston

维修须知

Maintenance instructions

故障排除

Troubleshooting

汽缸的拆卸

Removal of cylinder

气门的检查

Inspection of valves

活塞的拆卸

Removal of piston

活塞、活塞环的检查

Inspection of piston and piston ring

活塞环的安装

Installation of piston ring

活塞的安装

Installation of piston

气缸体的安装

Installation of cylinder body

维修须知

Maintenance Instructions

总则

General

注意事项：

Notes:

● 缸头润滑油是经由发动机右体

栓旁边的油孔到汽缸头的，在安装汽缸之前，应确保右体

栓旁边的油孔畅通。

Cylinder head lubricating oil is supplied to the cylinder head through the oil hole beside the
AB bolt on the right engine body; before cylinder installation, make sure the oil hole beside
AB bolt of right body is unblocked.

● 不能使灰尘或尘埃渗入曲轴箱内。

Prevent dust or dirt from entering the crankcase.

各部规格

Parameters of Components

项目

Item

标准值

Standard Value

(mm)

维修极限值

Maintenance Limit

Value (mm)

汽缸

Cylinder

汽缸内径

Inner diameter of cylinder

～

74.01

74.018

圆度

Roundness

0.004 0.008

缸面平面度

Planeness of cylinder face

0.03 0.06

活塞

活塞环活

塞销

活塞外径

Outer diameter of piston

73.96

～

73.97

73.94

活塞销孔内径

Inner diameter of piston pin hole

16.001

～

16.006

16.015

Содержание CBS300

Страница 1: ...50 1 Page 1 of 50 CBS300 CBS300 Engine Maintenance Manual Prepared by Checked by Reviewed by Approved by...

Страница 2: ...er element Lubrication method Pressure splash Starting method Electric Max power corresponding speed 18 5 1 5 kW 8500 1 5 rpm Max torque corresponding speed 22 1 5 N m 7000 1 5 rpm Idle speed 1400 100...

Страница 3: ...0 3 Page 3 of 50 Item Specification Ignition System Ignition method Capacitor discharge Spark plug CR8EB Spark plug gap 0 7mm 0 8mm Fuel Fuel grade RQ90 Engine oil Specification SJ 10W 40 Capacity 1 3...

Страница 4: ...t contact surface Assembling of cylinder head Assembling of cylinder head cover Installation of cylinder head Installation of cylinder head cover Maintenance Instructions Notes The camshaft is lubrica...

Страница 5: ...age 5 of 50 Item mm Standard Value mm mm Maintenance Limit Value mm Radial clearance between rocker arm and rocker arm shaft 0 016 0 045 0 08 Valve clearance 0 02 0 04 Camshaft base circle run out 0 0...

Страница 6: ...ge of valve spring 2 Cylinder head Loose connection between spark plug and cylinder head Damage of cylinder head gasket Cracks and sand holes on cylinder head 3 Cylinder body piston piston ring Excess...

Страница 7: ...head bolts 2 small GB T16674 M6 20 pan head bolts 1 small GB T16674 M6 32 pan head bolt 1 small GB T16674 M6 28 pan head bolt and 2 large GB5789 M6 65 pan head bolts on cylinder head cover Note 2 6 2...

Страница 8: ...cket head bolts fastening the tensioner and then the tensioner and tensioner sealing gasket Note O Prevent the O ring on tensioner from falling off 4 6201 Remove camshaft bearing 6201 and bearing baff...

Страница 9: ...nd the 0 intake and s well as in bling of Cyl ractor to pre ve the valve loosen the v spring retai permanent ng it shall y but as mo t can be rem rts remove as to mou cations dur er Head Co 50 NC250 r...

Страница 10: ...bnormal w valve stem m 1 5 t value for surface o nly abraded valve seat sealing pe replaced ocker Arm a Shaft r arm for w m roller for a amage or fo ker arm rolle with a new o arm shaft fo e rocker ar...

Страница 11: ...camshaft for crack and fracture and the reducing valve flail block and spindle for looseness if any the reducing valve flail block assembly shall be replaced Inspection of Cylinder Head 1 Check the cy...

Страница 12: ...alve guide is heavily worn the cylinder head shall be replaced Width Measurement of Valve Seat Contact Surface 1 5 mm Maintenance limit value 1 5 mm If the valve measured is too wide too narrow or pit...

Страница 13: ...y but as moderately as the valve collet can be mounted 2 Mount the collet properly into the circular valve groove and then tap the upper valve seat slightly and axially from the valve to ensure the co...

Страница 14: ...e bolt in the corresponding hole on cylinder head cover and tighten it Note 1 During mounting of rocker arm shafts the trimmed side of rocker arm shaft shall face the top of cylinder head cover and th...

Страница 15: ...n them Note 1 Prevent dust and dross from entering the cylinder 2 A B 40 45N m Tightening torque of AB bolts 40 45N m 5 6201 Mount camshaft onto cylinder head and timing chain onto timing driven sproc...

Страница 16: ...d timing marks pay attention to observing whether the timing mark on timing driven sprocket and the cover closing face are on the same plane 2 3 The engine is in the correct timing position only when...

Страница 17: ...e jointing faces of cylinder head cover and cylinder head and apply a layer of silicon rubber as the planar sealant on the jointing face of cylinder head cover 2 Mount cylinder head cover onto cylinde...

Страница 18: ...N m Mount the valve chamber covers onto the cylinder head cover and tighten them with small GB T16674 M6 20 pan head bolts tightening torque 11 13N m 6 2 GB5789 M6 28 1 Mount the starting motor in the...

Страница 19: ...l is supplied to the cylinder head through the oil hole beside the AB bolt on the right engine body before cylinder installation make sure the oil hole beside AB bolt of right body is unblocked Preven...

Страница 20: ...nce between piston ring and piston ring groove Top ring 0 03 0 07 0 08 Second ring 0 02 0 06 0 08 Clearance between cylinder and piston 0 035 0 045 0 07 Outer diameter of piston pin 15 994 16 15 99 Cl...

Страница 21: ...pis on of piston or cylinder w nder cylinder hea de 5789 e 2 large ts water pipe ove cylinder owel pin linder Body cylinder bo inner diame ns namely m of pisto t shall be irections 018mm value 74 Tro...

Страница 22: ...8 mm e oil ring 0 0 k the piston ring groove the piston r ure the end enance limit 0 5mm rst ring 0 5m 0 5mm econd ring 0 1 4 mm g 1 4mm on on pin retain s and then r tainer from en removing ston and...

Страница 23: ...limit ure the oute 15 9 enance limit out the cle pin 0 02 enance limit r diameter o 015 mm value 16 7 mm er diameter mm from pist 94 mm value 73 arance betw 7mm value 0 07 r diameter o 99 mm value 15...

Страница 24: ...on Ring piston ring g ston ring maging th g when mou splacing t ngs when g ed sides o ngs shall f allation pis e of rotating etween ring h the clea uring installa ll be mounte ston piston pin IN ston...

Страница 25: ...yer of engine oil on surfaces of cylinder body piston and piston ring 3 120 Stagger the opening of piston ring for 120 and then slightly mount the cylinder body in place 4 Mount the chain slide in pla...

Страница 26: ...of clutch housing Inspection of driving gear Inspection of oil pump Inspection of gearshift mechanism Assembling of water pump Installation of driving gear Assembling of gearshift mechanism Assemblin...

Страница 27: ...free stroke 1 Excessive free stroke 2 Bending of clutch driven plate 2 Bending of clutch driven plate Difficulty in clutch operation Excessive pressure of handle 1 Clutch housing sliding groove havin...

Страница 28: ...and take out the oil screen assembly or remove the bleeding bolt on the bottom and wait until the oil is completely discharged 2 10 GB16674 M6 40 1 GB16674 M6 50 Remove the 10 small GB16674 M6 40 pan...

Страница 29: ...gs 9 4 2 4 Removal of Gearshift Mechanism 1 Remove the shift arm components 2 GB119 1 4 10 Remove the pentagram shaped plate fastening bolt and spring shim and then remove the pentagram shaped plate a...

Страница 30: ...cove he copper g water pum of expans water pump g water pump g of Clutch Assembly clutch cover spring and move the frict f Right Cran crankshaft over for dam replaced wi to the follow g the crank het...

Страница 31: ...nspection o k the locatin e rotation h driven pl arance gaug mm value 0 11 nce betwee mm value 0 6m n of Clutch grooves on d y gap and sc or serious g replaced on of Drivin g gear for w ous wear a be...

Страница 32: ...water pump cover 4 2 Mount 2 dowel pins and mount the water pump cover onto the water pump 5 3 GB16674 M6 45 6 2 1 12 Fasten the water pump cover with 3 small GB16674 M6 45 pan head bolts and pay att...

Страница 33: ...ing gear locknut 50 65 N m Assembling of Gearshift Mechanism 1 Mount the locating plate assembly onto the right body and tighten it 2 Mount the pentagram shaped plate in the gear shift drum and pay at...

Страница 34: ...1 2 O 9 4 2 4 Put 2 O rings 9 4 2 4 into corresponding holes 2 Mount the oil pump to the corresponding position and pay attention to arrow which shall point to the main shaft O 9 4 2 4 O ring 9 4 2 4...

Страница 35: ...bush washer onto the main shaft Note Evenly apply lubricating grease on inner ring of clutch shaft sleeve 2 Mount the retainer in the corresponding groove on main shaft 3 Mount bearing and pushrod on...

Страница 36: ...ing and driven balance gears Installation of driving and driven balance gears Installation of magnetor rotor Installation of magnetor stator Installation of gear indication harness Installation of lef...

Страница 37: ...3 5 GB16674 M6 40 2 GB16674 M6 50 1 GB16674 M6 25 Remove the left cover bolts 5 small GB16674 M6 40 pan head bolts 2 small GB16674 M6 50 pan head bolts and 1 small GB16674 M6 25 pan head bolt 4 2 Rem...

Страница 38: ...ed that the magnetor rotor is impacted by accident during removing and assembling such as falling onto the ground or being knocked by a foreign object it shall be replaced with a new one Removal of Dr...

Страница 39: ...e gear indication harness Note O Take out the gear indicator together with its O ring Inspection of Left Crankcase Cover Check the left crankcase cover for breakage etc Inspection of Magnetor Stator a...

Страница 40: ...e driving gear locknut Note 1 Oil on driving gear locknut and left crank threads shall be cleaned up 2 M24 1 3 4 263 Apply the Loctite 263 thread locker on 3 4 threads whole circle of balance shaft lo...

Страница 41: ...unting the driving and driven balance gears namely the driving and driven balance gear teeth with timing marks shall mesh with each other 2 3 4 263 Apply the Loctite 263 thread locker on 3 4 threads w...

Страница 42: ...end of the duplicate gear II has one gasket 10 5 0 5 18 2 Mount the magnetor rotor onto the left crank and fasten it with the locknut Note 1 3 5 7262 Apply the HUITIAN 7262 anaerobic thread locker on...

Страница 43: ...n Note O Before installation make sure the O ring is intact on the gear indicator and replace it in case of damage 2 2 Fasten the gear indicator with 2 pieces of gear indicator bolts 5 7N m Torque of...

Страница 44: ...with the cable crimping board 5 GB16674 M6 12 Fasten the cable crimping board with GB16674 M6 12 bolts Note 8 12 N m Tightening torque 8 12 N m Installation of Duplicate Gear Cover 1 Mount the duplic...

Страница 45: ...Assembling of oil screen Assembling of transmission crankshaft balance shaft Crankcase assembling Maintenance Instructions This section describes the installation and detection of transmission cranks...

Страница 46: ...learance on big end side of connecting rod Axial 0 1 0 3 0 5 Radial 0 008 0 016 0 02 Balance shaft Shaft diameter 19 98 19 993 19 96 Troubleshooting Difficulty in gear shifting Crankshaft having noise...

Страница 47: ...ead bolt M6 100 pa 2 rd and re and then rem and the 2 d nkshaft Bal Counter Sh e fork shaft and cou crankshaft a parts are le main and tion of Cran V rankshaft b n radial run auge rance on th th a fee...

Страница 48: ...well as e bearings or flexible ro ation or seiz aced with th her the oil hift arm on se of damag h those on of Shift For Gear Shift fork for wea measure the 12 020 mm value of for shaft for w asure i...

Страница 49: ...Check the oil screen for damage if any replace it with a new one Assembling of Oil Screen 1 Mount the oil screen and spring in corresponding holes on the left case body 2 Mount the oil screen cover N...

Страница 50: ...se body Note The left crankshaft bearing requires interference fit with the crankshaft hole and shall be mounted in a shrinkage fitting way namely before installation bake hot the left crankshaft hole...

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