[5] CYLINDER; Cylinder Wear; Cylinder Correction (Oversize)- Page 239

ENGINE

L3560, L4060, L4760, L5060, L5460, L6060, WSM

1-S92

[5] CYLINDER

Cylinder Wear

1. Measure the I.D. of the cylinder at the 6 positions (see figure)

with a cylinder gauge.

2. Find the maximum and minimum inner diameters.

3. Find  the  difference  between  the  maximum  and  the  minimum

inner diameters.

4. If the maximum I.D. or the difference is more than the allowable

limit,  bore  and  hone  it  to  the  oversize  dimension.  (Refer  to

"Cylinder Correction (Oversize)"

.).

5. Examine  the  cylinder  wall  for  scratches.  If  you  find  deep

scratches,  bore  the  cylinder.  (Refer  to 

"Cylinder Correction

(Oversize)"

.)

9Y1210824ENS0104US0

Cylinder Correction (Oversize)

1. If the cylinder wear is more than the allowable limit, bore and

hone it to the specified dimension.

2. Replace the piston and piston rings with oversize ones.

Oversize : 0.25 mm (0.0098 in.)

NOTE

• If the maximum I.D. or the difference for the oversize

cylinder is more than the allowable limit, replace the
cylinder block with a new one.

9Y1210824ENS0105US0

Cylinder I.D.

Factory specification

87.000 to 87.022 mm

3.4252 to 3.4260 in.

Allowable limit

87.170 mm

3.4319 in.

Difference between 

maximum I.D. and 

minimum I.D.

Allowable limit

0.15 mm

0.0059 in.

(A) Top
(B) Middle
(C) Bottom (Skirt)

(a) Right-angled to Piston Pin
(b) Piston Pin Direction

Oversize cylinder I.D.

Factory specification

87.250 to 87.272 mm

3.4351 to 3.4359 in.

Allowable limit

87.420 mm

3.4417 in.

Difference between 

maximum I.D. and 

minimum I.D.

Allowable limit

0.15 mm

0.0059 in.

Finishing

Hone to 2.2 to 3.0 µmRz

(0.000087 to 0.000118 in.Rz)

(1) Cylinder I.D. (Before Correction)

(2) Cylinder I.D. (Oversize)

KiSC issued 03, 2016 A