5.16 ServiceManual-RocketIll

7. Thepistonringgapsmustbearrangedasshowninthediagrambelow.

FRONT

3=

Pistonringidentificationmarks

2. Installanewcircliptoonesideofthepiston.

3. Locatethepistontotheconnectingrodensuringthatthepistondirectionarrowpointstotherighthand(exhaust)sideoftheengine.

1.Piston

2.Directionarrow

4. Alignthesmallendintheconnectingrodwiththegudgeonpinholeinthepiston.

5. Lubricatethepiston,smallend andgudgeonpinwithcleanengineoilandfitthegudgeonpinfromtheoppositesidetothe installedcirclip.

6. Fitanewcircliptotheremaininglocationinthepistonthencheckthatbotharecorrectlyinstalled.Rectifyifnecessary.

1. TopRing

2. SecondRing

3. SteelOilControlRings

8. OilControlRingExpanderNote:

   • The topringgapshouldbepositionedinthe7o'clockposition,thesecondringgapinthe1o'clockpositionandthesteeloilcontrolringgapsinthe9&3o'clockpositions(oneineachposition).

9. Fitthepistoninto thebottomofthelinerusingagentlerockingmotion toengagetheringsinthebore.

Fittingapistonintoaliner

ServiceManual-RocketIll

5.17

CylinderWear

1.MeasuretheinternaldiameterofeachcylinderlinerusinganinternalmicrometerorMercergauge.Alwayscheckintwoplaces,at90°toeachother,aswellasatthreeheightsintheliner.

Cylinderlinerinternaldiameter
Standard	101.591-1.609mm
Servicelimit	101.659mm

Checkthediameteratpoints 1,2and3.

_1-- -2--

3

CylinderLiners

Removal

1. Markeachlinertoidentifycorrectorientationandthecylindernumberfromwhichithasbeenremoved.

2. Turnthecrankshaftuntilthepistonintheliner toberemovedisatthebottomofitsstroke.

3. CheckthatthelockingnutontoolT3880061isloose,thenfullyunscrewtheextractionnut.

gaep

2.

CheckingPositionsForBoreWearCheck(boreshowninsection)

If anyreadingisoutsidethespecifiedlimits,replacethe linerandpistonasanassembly.

Cbxz

1.ToolT3880061

2. Lockingnut

3. Extractionnut

^5.18 ServiceManual- Rocket Ill

4.Carefullyfittherubbersectionofthetoolfullyintothecylinderliner,positioningstudsssuppliedwiththetooldiagonallyacrossapairofheadbolt-holes.

1. Cylinderliner

2. Studs

3. Head-boltholes

5. Fullyengagetheboltthreadsintheheadboltholes.Itisnotnecessarytofullytightenthebolts.

6. Turnthelockingnutclockwiseuntiltherubbersleeveonthetooltightlygripstheboreoftheliner.

7. Turntheextractionnutclockwisesufficienttoraisethelinerandbreakthesealbetweenthelinerandcrankcase.

Note:

• Itisnotnecessary(orpossible)tofullyextractthelinerusingthistool.Oncethesealisbroken, thetoolmustberemovedandthelinerextractedbyhand.

Turnthelockingnutanticlockwise toreleasetheliner.

Oncethesealonthelinerisreleased,removethetoolandmanuallyremovetheliner.

Installation

1. Thoroughlycleanthelinerremovingalltracesofoldsiliconesealer.

2. Removealltracesofsealerfromthecrankcasebores.

3. Applyathinbeadofsiliconesealertothelinertocrankcasematingface.

1.Liner

2.SealerArea

4. Applyathinbead ofsiliconesealertothelinertocrankcasematingface.

1ri----L

1.Liner

2.Sealerarea

ServiceManual-Rocket Ill

5.19

5. Carefullyfiteachlineroverthepistonusingagentlerockingmotiontoallowcompressionofthepistonrings.

Fittingapistonintoaliner

Note:

• Thelinershave alargechamferatthebottomofthebore,enablingfittingofthepistonwithoutneedforapistonringcompressor.

5. Continuefittingeach linerinturnuntilallarefittedandsealed.

Note:

• Whenthelinershavebeenfitted,theyshouldnotbedisturbed.Ifitisnecessarytoremovethelinerafterfitting,thesealermustbere-applied.