7-9
Chapter 7 ASSEMBLY OF BASIC ENGINE
(5) Calculate the cylinder liner flange protrusion by sub-
tracting the depth of counterbore in crankcase from the
thickness of the cylinder liner flange.
If the value exceeds the limit, insert a shim under the
cylinder liner flange. Select a shim which makes the
cylinder liner flange protrusion the largest within the
tolerance of the standard.
Note:(a) Shims are available in 3 sizes: 0.05, 0.10 and 0.15
mm [0.0020, 0.0039 and 0.0059 in.]
(b) Do not double the shims.
Shim - Insert
2.3 Cylinder Liner - Install
(1) Install the O-rings to the cylinder liner.
(2) Insert the shim to the cylinder which needs the adjust-
ment of cylinder liner flange protrusion.
(3) Apply engine oil to the O-ring fitting bore in Crankcase
and cylinder liner O-ring sliding surfaces.
Cylinder Liner O-Rings - Install
(4) Slowly insert the cylinder liner into the bore in the
crankcase. With a correct cylinder liner installer, lightly
tap the cylinder liner until its flange contacts snugly on
the seating surface of the crankcase. Then, lightly tap
the liner several times to verify the stable seating.
Note: To verify the correct O-rings installation, measure the
roundness of inside diameter of the cylinder liner (es-
pecially O-ring installing position.)
Cylinder Liner - Install
Item Standard value
Cylinder liner flange protrusion
0.11 to 0.20 mm
[0.0043 to 0.0079 in.]
Shim thickness Part No.
0.05 ± 0.02 mm
[0.0020 ± 0.0008 in.]
37507-12510
0.10 ± 0.02 mm
[ 0.0039 ± 0.0008 in.]
37507-12500
0.15 ± 0.02 mm
[0.0059 ± 0.0008 in.]
37507-12520
Shim
Crankcase
Cylinder liner
Apply engine oil to the O-ring sliding surfaces to pre-
vent O-rings from twisting.
Do not apply engine oil to the O-ring grooves on cylin-
der liner.
O-ring
Installer
Cylinder liner
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