User manual CANNONDALE 2002, 2001 ENGINE SERVICE MANUAL

[. . . ] 1 P/N 941 5002037 Printed : 8/27/01 AB O U T T HE M A N U A L This is an "engine" service manual. It has been developed to address major mechanical service issues (example: component and systems removal, inspection, disassembly, assembly, and reinstallation. ) This manual can be used for 2001 and 2002 Cannondale vehicles (motorcycles & ATVs). You must possess significant mechanical knowledge, skills, and tools to perform most of the procedures found in this document. This manual was accurate at the time of publication. [. . . ] Then, use the piston to position the ring to a depth of 10 mm inside the sleeve and at a right angle to the sleeve bore. Measure the ring end gap. b a a a. Skirt diameter O. D. Piston skirt O . D. standard - 7. 7368 - 3. 7371 in (94. 915 - 94. 925 m m ) lim it - 3. 7346 in (94. 860m m ) a. Depth 4. Use a feeler gauge to measure ring-side clearance. If out of specification, replace piston and rings. Piston, top ring, end gap standard - 0. 014 ~ 0. 0022 in (0. 35 ~ 0. 55 m m ) lim it - 0. 0334 in (0. 85 m m ) Piston, 2nd ring, end gap standard -0. 014 ~ 0. 0022 in (0. 35 ~ 0. 55 m m ) lim it - 0. 0334 in (0. 85 m m ) 7. Inspect piston pin for discoloration and grooves. a. Ring side clearance 85 P/N 941 5002037 Printed : 8/27/01 8. Take measurements in the X and Y axis and take the maximum reading. PISTON, ASSEMBLE CAUTION Do not over lap the ends of the oil expander; excessive oil usage will occur and the engine will smoke. The engine may be damaged. a x y Install top and second ring with the manufacturer's mark up. a. Piston wrist pin bore I. D. NOTE : The piston has an arrow mark on the exhaust side. 9. Install the oil ring expander into the piston oil ring groove with the butted tips facing the intake side of the piston. Be sure the tips are butted together and not overlapped. Install the upper (above the expander) and lower (below the expander) oil rings onto the piston. Position each of the three rings. a a. Piston wrist pin 0. D. c 10. Calculate the piston wrist pin-to-piston pin bore clearance. 0. 708 ~ 0. 709 in (17. 995 ~ 17. 998 m m ) Piston w rist pin bore I. D . 0. 7089 - 0. 7090 in (18. 005 ~ 18. 010 m m ) Piston-to pin-clearance standard - 0. 0002755 ~ 0. 00059 in (0. 007 ~ 0. 015 m m ) ESM Body. fm © 2001 Cannondale Corporation - All Rights Reserved a INTAKE SIDE VIEW a. c. Oil ring (butted end) Lower oil ring gap Upper oil ring gap 86 2. Install the 2nd ring onto piston with the manufacturer's mark facing up. Install the first ring onto the piston with the manufacturer's mark facing up. 4. Position all illustration. ring gaps according to the EXHAUST Oil Ring (lower) 2nd Ring UP 1st 1st Ring WRIST PIN BORE Oil Ring (upper) UP 2nd Oil Ring Expander INTAKE MARK 1st Ring 2nd Ring Oil Ring SIDE VIEW PISTON, INSTALL 1. Refer to "Sleeve (and piston), install" starting on page 88. 87 P/N 941 5002037 Printed : 8/27/01 SLEEVE (AND PISTON), INSTALL 3. Install a new right side wrist pin circlip with the flat side of the clip facing out of the pin bore. [. . . ] Tighten the bolt to the specified torque. CAUTION The generator cover seal is re-usable. A damaged seal will allow contaminants to enter and cause damage. 1. Remove the cover bolts, cover and seal. Ignition coil retaining clip bolt 3. 3 lbf·ft (4. 5 N ·m ) 1 1. Cover 2. To install, place the seal onto the cover and install cover. [. . . ]