Kymco MO X500 Service Manual - chap 09 (cilindro pistone)
9. CYLINDER/PISTON
XCITING 500
9
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CYLINDER/PISTON
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SCHEMATIC DRAWING ------------------------------------------------- 9-1
SERVICE INFORMATION------------------------------------------------ 9-2
TROUBLESHOOTING----------------------------------------------------- 9-2
CYLINDER/PISTON REMOVAL---------------------------------------- 9-3
CYLINDER/PISTON INSTALLATION--------------------------------- 9-7
9
9-0
9. CYLINDER/PISTON
SCHEMATIC DRAWING
XCITING 500
9-1
9. CYLINDER/PISTON
m
d
r
XCITING 500
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The cylinder and piston can be serviced with the engine installed in the frame.
• When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are
correctly installed.
• After disassembly, clean the removed parts and dry them with compressed air before inspection.
SPECIFICATIONS Unit: mm (in)
Ite
I.D. 92.005 (3.6802)～92.015 (3.6806) 92.1 (3.684)
Cylinde
Piston, Ring end gap Second
piston ring Oil side rail
. Piston-to-cylinder clearance
Piston pin O.D
Piston-to-piston pin clearance
Connecting rod small end I.D. bore
Warpage
Cylindricity
True roundness
Ring-to-groove top
clearance
Piston O.D.
Piston O.D. measuring position
Piston pin hole I.D.
Second
top
Standar
0.01 (0.0004)
0.01 (0.0004)
0.01 (0.0004)
0.03 (0.0012)～0.065 (0.0026) 0.08 (0.003)
0.015 (0.0006)～0.05 (0.002) 0.065 (0.0026)
0.15 (0.006)～0.3 (0.012) 0.5 (0.02)
0.03 (0.012)～0.45 (0.018) 0.65 (0.026)
0.2 (0.008)～0.7 (0.028)
91.96 (3.6784)～91.98 (3.6793) 91.9 (3.676)
10 mm from bottom of skirt －
0.01 (0.0004)～0.045 (0.0018) 0.1 (0.004)
22.002 (0.8801)～22.008 (0.8803) 22.04 (0.8826)
21.994 (0.8798)～22 ( 0 . 8 8 ) 21.96 (0.8784)
0.002 (0.0001)～0.014 (0.0006) 0.02 (0.001)
22.016 (0.8806)～22.034 (0.8814) 22.06 (0.8824)
Service Limit
0.05 (0.002)
0.1 (0.004)
0.1 (0.004)
1 (0.04)
TROUBLESHOOTING
• When hard starting or poor performance at low speed occurs, check the crankcase breather for
white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.
Compression too low or uneven
compression Excessive smoke from exhaust muffler
• Worn or damaged cylinder and piston rings • Worn or damaged piston rings
• Worn, stuck or broken piston rings • Worn or damaged cylinder and piston
Compression too high Abnormal noisy piston
• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings
chamber or on piston head • Worn piston pin hole and piston pin
• Incorrectly installed piston
9-2
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