There is a false idea that broken . Let us hasten to dispel these incorrect judgments - a scooter that has undergone a major overhaul, for example, or a “two-wheeled horse” that has survived the replacement of an engine or any other important component, also needs a break-in.
Know that the duration of the flawless operation of your “pet” depends on how competently and efficiently the running-in of your unit . The main breakdowns of scooters at the turn of 500 to 1000 kilometers occur, as a rule, not only due to manufacturing defects, but in most cases due to incorrect running-in conditions. Proper running-in is especially true for Chinese-made scooters.
How long does it take to break in a moped?
It is necessary to constantly monitor the thermal conditions of the engine, and start driving only with a fully warmed up engine. The break-in period is 1000 km, but even after this period it is not allowed to suddenly switch to load modes.
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Why is this run-in necessary in principle?
In a new (or repaired) engine, all its constituent elements: piston, gears, crankshaft, and all other parts must be ground in. An important condition for running in is a gentle regime. Each manufacturer determines the duration of the break-in. As a rule, this segment fluctuates around a thousand kilometers. During this period, the owner is obliged to move at a speed not exceeding 80% of the maximum possible on this unit. From which it follows that for now you should forget about full throttle, and also refuse to drive for a long time at a constant speed. Simply put, you can drive at a speed of no more than 40 km/h, even for a city this is quite enough.
So it’s in your best interests to be patient for the first thousand kilometers.
Features of running a scooter after replacing the piston
To give recommendations for running-in after repair, you should first consider the reasons leading to the repair and methods of restoration. After a comprehensive piston replacement, mandatory running-in of the power unit is required. It should be noted that it is not necessary to resort to replacement if any problems arise with the vehicle, be it poor acceleration, lack of normal starting, and so on. Practice shows that there are only two reasons for a comprehensive piston replacement:
- gradual wear of the piston and cylinder, which leads to poor compression inside the combustion chamber;
- the appearance of scuffing inside due to foreign objects getting into the structure, failure of rings, and so on.
To determine the presence of poor compression, it is enough to use a special device - a compression meter. Having discovered that the compression ratio is less than 7.0 atm, you should think about completely replacing the piston group.
What to do if you don’t have a compression gauge on hand? In this case, the check is carried out in the following way. If you think that the moped is difficult to start due to low compression, just pour a little engine oil into the spark plug hole. Having discovered that the engine starts to start better, the absolute cause of the problem is the presence of poor compression in the engine.
What to do if wear occurs?
Having discovered that the problem lies in the failure of the cylinder-piston group (CPG), you can use two methods. The first is to purchase the entire CPG, but this option requires large financial investments. However, the owner will not have to waste time searching for a turner on his own and will be able to complete the replacement procedure without outside help.
On the other hand, if you have an original cylinder, it becomes possible to bore the worn-out one using turning equipment. The procedure is as follows: the owner takes the old cylinder with him to the turner. The specialist visually assesses the condition, after which he indicates the repair size. There are four in total:
These numbers indicate an increase in millimeters to the existing diameter. This amount of metal is ground down during processing of the internal walls of the cylinder
When boring, the coefficient of thermal expansion of the metal that occurs during engine operation must be taken into account. Therefore, another fifth hundredth of a millimeter (0.05) is added to the indicated number
This will not affect the compression level in any way, and the power unit will not receive a temperature wedge. After assessing the bore diameter, you will have to buy a repair piston. Having purchased it, they pass it along with the cylinder to the master for boring.
Features of removal and installation
First rule. When performing work, it is imperative to maintain cleanliness. Before dismantling the power unit, you should go to the car wash and remove all remaining dried dirt and dust using a high-pressure washer. Using a special cleaning agent, the engine housing is washed. You cannot wash a hot engine, since a sudden temperature change has a negative effect on the engine. Be sure to disconnect the battery. As soon as the body is processed, you need to wait a while until the motor dries out. Using compressed air from the compressor, remove all drops of water, and also treat the wire connections.
How long does it take to run an engine after a major overhaul?
Engine running-in is performed in cases where the engine has just been released by the manufacturer or after a major overhaul. Engine running-in usually lasts 2–3 thousand kilometers. Compliance with the engine break-in regime is necessary due to the fact that new parts require “grinding in”.
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What to do if wear occurs?
Having discovered that the problem lies in the failure of the cylinder-piston group (CPG), you can use two methods. The first is to purchase the entire CPG, but this option requires large financial investments. However, the owner will not have to waste time searching for a turner on his own and will be able to complete the replacement procedure without outside help.
On the other hand, if you have an original cylinder, it becomes possible to bore the worn-out one using turning equipment. The procedure is as follows: the owner takes the old cylinder with him to the turner. The specialist visually assesses the condition, after which he indicates the repair size. There are four in total:
These numbers indicate an increase in millimeters to the existing diameter. This amount of metal is ground down during processing of the internal walls of the cylinder
When boring, the coefficient of thermal expansion of the metal that occurs during engine operation must be taken into account. Therefore, another fifth hundredth of a millimeter (0.05) is added to the indicated number
This will not affect the compression level in any way, and the power unit will not receive a temperature wedge. After assessing the bore diameter, you will have to buy a repair piston. Having purchased it, they pass it along with the cylinder to the master for boring.
Features of removal and installation
First rule. When performing work, it is imperative to maintain cleanliness. Before dismantling the power unit, you should go to the car wash and remove all remaining dried dirt and dust using a high-pressure washer. Using a special cleaning agent, the engine housing is washed. You cannot wash a hot engine, since a sudden temperature change has a negative effect on the engine. Be sure to disconnect the battery. As soon as the body is processed, you need to wait a while until the motor dries out. Using compressed air from the compressor, remove all drops of water, and also treat the wire connections.
Second rule. Keep track of how the parts were before disassembly. It is best to use a digital camera or a smartphone with a good camera. Use your camera to take step-by-step photographs of the parts being disassembled.
First you need to dismantle the power unit. It is noteworthy that in some scooter models - for example, Honda Dio before 1994, you can completely replace the piston without removing the entire engine. Disassembly order:
Unscrew and remove all parts that interfere with dismantling - throttle cables, rear brake cables, fuel and oil supply hoses, electrical blocks, shock absorber, and so on. In most models, the engine is secured with just one bolt to the frame. Unscrew it and roll out the engine. Remove the muffler, air filter, cylinder and generator casing. Using a compressor and brush, completely remove any dust from the cylinder. If necessary, wash the cylinder again. The part must be perfectly clean. Unscrew the spark plug and unscrew the nuts/bolts that secure the cylinder head. Before performing work, be sure to wash all the places where the crankcase is connected to the cylinder. Even if the engine was washed anyway, there will always be sand and dirt under the fins. When removing the cylinder, residual dirt may penetrate inside the crank chamber. Unscrew the head and then proceed to dismantle the cylinder. In some cases, it happens that the cylinder is stuck and does not want to be removed easily. Here you need to pick it up using a pry bar. If you find that the cylinder gaskets are coming off in pieces and are stuck to a metal surface, you should carefully and carefully remove them
It is important to achieve maximum surface evenness. If there is no gasket to replace, you need to buy a new one or a paronite sheet and cut a new gasket out of it
It also happens that during the repair process the owner damaged the aluminum gasket located between the cylinder and the crankcase. You can do it yourself and make a new gasket using a cola can. But before that you need to completely remove all traces of paint. A clean cloth should be placed between the crankcase walls and the connecting rod to prevent foreign objects from getting into the crankcase. If this requirement is not met, the new cylinder-piston group will most likely fail in the future, and the crankshaft will also break. To squeeze out the pin, you must first remove the stopper from the piston pin. Always remember that the finger fits quite tightly, so you will have to make a lot of effort to remove it. While pushing out the pin, make sure there is no lateral load on the connecting rod. Otherwise, you will have to purchase a new one, since the old part in this condition is not subject to further use. The operation must be performed so that the piston rests against an object sideways. You can support it on the wall by laying a piece of wooden beam. Remove the piston and get rid of the cage bearing. The old gasket should also be removed.
After completing all the work to dismantle and restore the cylinder-piston group, it is necessary to perform the installation in the reverse order.
