Flex-honing cylinder wall

AR01.40-I-9211B

Flex-honing cylinder wall

25.6.07

1

Remove piston on cylinder bore to be machined

Engine 904.925/965

Engine 904.941:

* only for Indonesia

AR03.10-I-7021B

2

Measure cylinder bore to be machined

Engine 904.925/965

Engine 904.941:

* only for Indonesia

AR01.40-I-9202B

3

Mask off openings in cylinder crankcase (1)

4

Cover crankshaft as well as crankshaft and connecting rod bearing with pieces of foam

 Lead pieces of foam through the cylinder barrel. Do not use cleaning cloth because these do not adequately absorb grinding residues and lubricant.

5

Clamp honing brush (2) into hand drill (3) and dip in lubricant

 Use honing oil, low-viscosity engine oil, kerosene or diesel fuel as a lubricant.

In order to avoid fouling the surrounding area and clothes place a protection box or some other kind of protection on the contact surface of the cylinder crankcase (1).

6

Hone cylinder barrel

 Only use a working speed of a maximum of 200 rpm otherwise the honing brush (2) can kink.

 Move honing brush (2) evenly upwards and downwards. The direction must be altered if about a quarter of the honing brush (2) overhangs above or below. The machining time is 1 to 2 min.

7

Clean cylinder barrel and check surface structure

 The grind pattern should be trapezoidal with an angle of 45° to the contact surface of the cylinder crankcase (1) and should appear matt.
If the surface is bright repeat machining.

8

Remove pieces of foam and eliminate grinding residues

 Use a clean cloth.

9

Remove masking on crankcase
(1)

10

Clean cylinder barrel with cleaning petroleum

11

Measure machined cylinder bore

Engine 904.925/965

Engine 904.941:

* only for Indonesia

AR01.40-I-9202B

12

Install removed piston

Engine 904.925/965

Engine 904.941:

* only for Indonesia

AR03.10-I-7021B