Tuning Gauges Eric Gorr-Books Pdf

TUNING GAUGES Eric Gorr
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Top end rebuilding is the most frequem or auto parrs s Ores Buy the threaded air causing the mixture to run lean and. and cmtiy service romine on rwo stroke type and make sure the kit comes with overheat the engine When the wer seal. dirt bikes Every year dirT bike riders an adapter that matches the spark plug wears the cr ll1kc lSe sucks in rranny. wasrc loads of money on rap end partS threads of your engine oil clLlsing the engine co run rich and. rhar didn t need to be replaced or they Performing a compression tesr is evenrually wet foul the spark plug. make costly misrake while performing simple Stan by removing the spark plug A crankcase pressure lest involves. repairs This seC ion provides the dos and threading in rhe adaprer and holding the the use of a vacuum pump wirh spark. don rs ro easy rap end rebuilding pius throttle wide open with the kill button plug adapter and rubber plugs to block. some tips that aren t printed Irl your on This prevenr any spark and enables off the intake and exhaust manifolds of. the cylinder The pi ron musr be posi, facrory service manual the engine to draw in maximum aitHow. Then kick Start the engine several times tioned ar BDC to allow the transfer. BEFORE YOU ST R lnril rhe needle on the pressure gauge pores co be wide open linking the bore. Thoroughly wa h your bike because dirr, sruck ro the underside of the rop frame. peaks The pressure reading depends on, twO main facrors the compression ratio. and the crankca e The hand pump, produces vacuum pressure up to a Stan. tube could break loose when servicing and the altitude at which rhe engine is dard setting of S psi The notmal. HJd hll inro rhe engine Use a sriff plastic tesred The ompression ratio will also bleed down pressure loss is 1 psi per. brush and hot soapy warer to clean off depend on wherher or not the engine minute Cylinders with complicated. the gtit and grime around the base of the is equipped with exhaust valves and exhausr valve systems can be difficult to. cylinder on the carbutetor and intake the condition of the wives When rhe block off air leaks and harder ro tesr. boot and especially underneath the rap exhaust valves are in the closed position Crankcase pressu re tesri ng lei ts are. ftame rai Degreaser can be used on the compression rario will be greater available f rom Morion Pro. metal surfaces bur take care nor to leave d1an if the valves are carbon se i7 ed in rhe If I Sllspecr thar an engine has an air. it on rubber or gasker surh ces open position The difference may yield leak in the crankcases I do d visllal test. a pressure reading of 25 psi The guality Starr by power washing rhe engine. TOOLS of compression testers varies gready clean Theo remove rhe magnetO cover. You ll need at least some 3 8 in drive The main thing thar a compression Spray thc magneto clean with an. merric sockets and box wrenches tester can idemi is a change in condi aerosol can of brake cleaner Make sure. open end wrenches will round off rhe tion Whenever you rebuild the top end to lise a non chlorinared cleaner. edges on the cylinder or head nutS take a compression pressu re reading Sprinkle baby powder on all the. and shouldn t be used fur rop end and mark ir down hcn the pressure suspect areas of the engine Sprin kJe. rebuilding needle nose pliers for, changes 20 percent check the condition the powder on the crankcase around.
removing circlips and a gasker tOol to of rhe piston and rings Pistons USU ll1y the magneto ar the crankcase seam. scrape the old gaskets away For soft last rwice as long as ring line the cylinder base and the reed. roob ger some shop rowels aerosol valve Run the engine for a while rhe. oven cleaner a Scorch Brire pad a CRANKCASE PRESSURETESTING white baby powder will highlight any. locking agent such as Loctite a gasket The crankcase of a two stroke engine is fluid or ait leaks on the engine The. scraper a brush and a bucker of soapy sealed off from the rranny II s impor baby powder tesr is Jnuch better than. water You ll also need a comptession tant thar the rwo crankshaft seals are in the alternarive rest of blowing raw. tesrer a feeler gauge and a digi ral oprimum condicion One side of the propane gas ar different areas of a. vernier caliper crankshaft uses a dry seal and the orher running engine and listening for a. a wer seal The dry seal runs on the change in the idle rpm Thar is. COMPRESSION TESTING magnero side and the wet seal runs in dangerous because it involves flam. A compression tester is a useful diag oil on the tranny side Xlhen rhe dry mable gas and a hot engine with. nostic rool read ily available from Sears seal wears rhe crankcase sucks in hot random eleerrical shorts. MAINTENANCE AND INSPECTION, DISPLACEMENT 80 cc 125 cc 250 cc 500 cc. TEAR DOWN AFTER 5 hours 10 hours 20 hours 40 hours. When you do a top end job check the condition of, the cylinder head The top end bearing of this bike. started to break apart and the needle bearings, smashed between the piston and head causing. damage to both The head was refinished on a lathe, I There are two ways to instaillhe top end You can. A thorough Op end rebuild requires Most cylinders use alignment pins to locate the instaillhe piston assembly I nto the cylinder and. removing the reed valve cyli nder head cylinder on the crankcase If those pins get tweaked then lower the piston and cylinder onto the. and cylinder You should tear down or rusty it may be difficult to bolt the cylinder 10 the connecting rod to pin it The conventional way IS 10. your rap end periodically and inspecr cases Sometimes stress fractures will occur on the install the piston assembly on the rod and lower the. the reed valve cylinder head cylinder cylinder or the case Check out this hairline crack In cylinder onto the piston Never twist the cylinder or. piston and so on Use the following the cases below the cylinder bolt rings when sliding the cylrnder and piston together. charr ro derermine when you should The ring ends can get trapped in the ports and be. tear down yom bike prone to cracking, Nore that air cooled bikes should CYLINDER HEAD.
be inspected lI10re frequendy Also you Check rhe head at the edge of the. may wam to nspeu more often if you are chamber for erosion marks a sign that angle AlLernJ le from lefr to righr sides. riding in fine sand or lars of mud When the head gasker is lealcing If d1e head or to lifr rhe cylinder Lip evenly Afrer you. yOll tear down the engine inspecr each rop edge of rhe cylinder is eroded ir must remove rhe cylinder sruff a shop rowel. sysrem and look for the following be turned on a lathe ro be reslIffaced inm Lhe open crankcases to prevent. trouble signs debris from enrering rhe engine, REED VALVE All cylinder bases lise aligning dowel THE DIFFERENT TYPES OF STEEl LINED. Check rhe reed perals tor open g lP pins around 0 of the cylinder base AND PLATED CYLINDERS. between the sealing surbces In rime sruds The pins are made of steel and T here are tv o r pe of yl inder bores. rhe reed petals lose rheir spring tension afrer heavy power washing Lhey get used on dirt bi kes sreel or casr iron. and rhe backHow can cause a flat spar corroded That makes it difficult ro sleeves or rhose wirh plaring on the. in rhe thronlc response Srock nylon remove the cylinder from rhe aluminum Mosr din bikes made after. reeds tend ro splir ar the edges on bikes crankcases Never use a pry bar Thar 1989 have plared cylinders You Cln. thar Ire cOlistanLiy over revved Experr will damage rhe cylinder Tnsread use a check rhe cylinder eype with a magnet. riders find rhar c rbon tiber reeds lasr plastic mallet to hir l1pward on rhe If the magner Slicks to rhe bore it is a. much longer sides of rhe cylinder ar a 45 degrec sleeve Jfir doest r stick it is plared. TWO STROKE TOP END REBUILDING, T11is IS aview looking down the exhaust pipe Notice. how carbon bUildup has reduced the diameter of the. pipe which can make the bl ke lose power and run, hotler lf your bike ever breaks a pislon power wash. the pipe to nush out the debriS Whenever the cylinder is overbored check the exllaust valve clearance to the bore These valves protrude too. far Into the bore and need to be ground for a pislon clearance of 1 mm. carbide panicles 1 wear resisranr marc HE PSTO, rial lhal c nries rhe load of the pisron Some uofonunare guys do more damage. The marerial is electro pia red righl on to replacing rbe pisron rhan he acrual wear. he aluminum cylinder lor he optimum on the pistoll Remove the circlips with. rhermal efllciency Nickel can be honed small needle nose pliers and rhrow them. wirh diamood srones which leave dislinc away It is a COillmon mistake to reuse. rive peak and valley scralches in the circlips hut the cheap spring sreel wire. cylinder wall lhal rerain oil and pro ide a clips will r ltigue and hreak if you insrall. cerrain bearing ratio hnween rhe running them for a second time. surfaces of rhe bore, After removing the cirdips you have.
lr s possihle ro rebuild a plared ro remove rhe pistOn pin Never use a. cyli nder by flni ng ir wirh a sleeve h lmnler and punch ro remove the pin. However yOLl can expecr ro pay more Thar will damage the connecring rod and. Some big bore kits have pistons larger than the hole for bore mainrel1ance over rhe life of needle bearings Instead use one of he. III he crankcases Clearance grinding is necessary rhe hike and lose rhermal efficiency and pin extracror rools available rrorn your. a rJ an be performed With careful tapmg and the, horsepower Plated cylinders are harder OGU franchised mororcycle hop You can. aid or avacuum cleaner and lasr longel dUll sleeved cylinders also grasp the piston wirh one hand and. Kawasaki cyli nder with the original use a 3 H in socket exrension to push rhe. Electrofu ion coaring or hard chromed pin our irh your other hand. There arc rhree rypes or pl lled cyJiflders can be repaired wit h n ickeJ Too many people replace their pisrons. cylinders Kawasaki FJecrrohlsion hard plating or sleevillg Sred or cast iron roo nllell The exact service inrerval f H. chrome llId nickel silicon carbide There sleeves can not be nickel plated unless your bike depends Oll how hard rhe bike. are several variarions of rhe nickel silicon hey are separated from the aluminum was run for how mallY hours th e quality. carbide process bur rhe ITlOSl common cylinder The pferrearl1lenr or rhe pia ring of rhe lubricarion and tbe amounr of din. trade name i Nika il The nickd would disinlegrare the aluminum or OLI er debris in rhe in ral e air Bikes thar. hased processe have many advanrages There are four companies that fe plate dre run hard wirh dirty air fillers may wear. over hard chrome Elecrrofusion and cylinders in rhe Unired Slates The Oll pistons il1 only six hour while bikes. skeving Nickel dLlraCIS oil and is an average COSt ro re pLlle a cylinder is that are ridden easy with clean filrers and. excellenl carrier material for silicon about 200 adequ Jre h ld octane may last lO hours. This Motion Pro piston pin extractor saves you from. hammering on the rod to remove the piston, Never use achisel to break the cylinder loose from the crankcase. MEASURING THE PISTON, It is best to measure the pismn with a. caliper Digital calipers cost abUliC 00, at industrial fOol companies such as. Enco or Harbor Freigh t A digital, caliper is easy to use and gives accurate.
measurements on rlle pisron diameter, and cylinder bore J 1easure the widths. of the pismn front ro back jusr above, the ilHake cmaway this is the widest. poim of the piston Check the, maxJmum wear specs In your service. manual Check the pisron for detona, rion marb in the crown cracks in the. skirt or seiwre marks Look at the, underside of the piston crown for a.
large black spot The spor is burnt oil, deposits that adhered ro the piston. because the piston crown remperature, wa too hot This is an indicacion thac. rhe carb s main jet needs to be richer, Use a plastic mallet to rock the cylinder up evenly Damage to the cylinder gasket sUliace might cause it to leok. LETTER DESIGNATIONS ON, CYLINDERS AND PISTONS, The Japanese manUFJHurerS use a leITcr and 0 006 in Tn the standard. designarion sysrem for plared cylinders Japanese alph 1 labding sysrem. They ilHend for you ro order replacement An denores rhe smallest bore or. pisrons based on rhe lerrer designation piston si e and every lerrer after. prinred or stamped on the cylinder In thar is slighrly larger lIsu tJ1y in. mass producrion you can t guarantee rhac incremenrs of 0 00 15 in If you try. all parrs will be exactly the same size The to put a D pi tOIl in an A cylinder. size variance is based on an acceptable rhe pisron to cylioder wall clear. level of quality Tool bits become dull ance will be so tight rllar a seizure. temperatures of machine tools change might occur, through production runs and machine.
operators have inconsisrenr performance, The Japanese manufacrurers have two ro Measure the piston at the bottom from front. four difFerenr sized pistons and cylinders to back Pistons are cam ground and. normally labeled A B C and D If they tapered specially for engine running condi. only had one size he piston to cylinder tions A 30 cali per is good enough 10 get an. wall elearance would vary between 0 00 I accurate measurement or the piston. semhling them Calltion Oven, cleaner macks aluminum don t. leave jt On the cylinder For more, than 20 minuLes Oven cleaner. ca n be used on borh steel and, p l1 red bores, The oven cleaner will help. TUNING GAUGES engine we He really talking abour a mixwre of fuel and oiL If yOll rjchen rhe pre mix ratio 20 1 as opposed w 30 1 rhere is more oil and less fuel in rhe same volunle ofliquid which eftec rively leans he air f1Je1 ratio Thi fau gives rhe clever uner one more rool ro use hen lhe corren jn is nor available or whe nooe of rhe tamhrd jets are exactly right

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