There are many possible reasons and factors that can cause seizure and ductility in 2-stroke engines. One of the factors that should be suspected is the "edge condition" of the intake and exhaust ports and scavenging ports. When a cylinder is disassembled into individual parts, the upper and lower edges of the intake and exhaust ports and scavenging ports should be checked for sharp edges or burrs! Be sure to check and take the best possible measures. If the skirt side under the piston rings is stained with carbon as shown in the image above , it is thought that explosive combustion gases are blowing into the primary compression chamber due to poor airtightness caused by worn piston rings. Therefore, replacement of piston rings or boring and honing of oversize pistons are essential.

Check when engine is disassembled and chamfering is performed when boring is performed.

When machining port chamfering on a 2-stroke cylinder, be careful to hold the cylinder firmly in place before working on it, or you may scratch or otherwise damage the cylinder's inner walls.

A solid workbench allows for a reliable chamfering process to proceed. The general user should proceed with the work by securely fastening the cylinder body to avoid scratching or damaging the cylinder.

The 2-stroke cylinder has numerous ports, and the temperature rise from explosive combustion can deform the port edges and damage the piston during reciprocating motion. This is where chamfering is essential.

Intake and exhaust ports immediately after boring and honing have sharp edges, so be careful!

The inner wall of a 2-stroke cylinder that has been bored to accommodate oversized pistons. This is how it looks immediately after boring. The internal combustion equipment maker chamfers each port before moving on to the honing process.

The workbench dedicated to port processing looks like this. It is gate-shaped and features a vertical cut pipe welded face down. Cloth duct tape is applied to the R surface of this half-pipe to prevent scratching the cylinder's inner wall.

There was an air duct right next to the workbench that efficiently sucked up the scattered cutting dust and collected it in a dust collector. Desk lights were placed in front of and facing each other to illuminate the work, allowing the port shape to be clearly seen.

Cutters and wheel bars are set on the pneumatic port grinder used during chamfering operations. The top one is a spherical super steel bar for cast iron cylinders and the front one is a rubber wheel bar for plated cylinders. Both are commercially available.

R-chamfering, which is gentle to the piston edge, is another important operation.

After chamfering the edges of the intake, exhaust, and scavenging ports of the cylinder with a port grinder, be sure to chamfer the piston skirt area as well. This is even more necessary for new pistons. Instead of chamfering the piston skirt, be sure to lightly rub the skirt edge with waterproof paper No. 600 or so.

The larger the ports on a 2-stroke high-performance engine, the higher the incidence of problems.

The 500H1 and 750H2 engines in the Kawasaki Mach series have particularly large intake and exhaust ports, which allow the pistons to pivot during reciprocating motion, causing each edge of the piston to collide with the port edge. This causes the inner walls of the cylinders and the top and bottom of the ports to reduce easily. Typical examples are the Kawasaki H1/H2, Yamaha 250DT1, Kawasaki 250TR Bison, and 350TR Bighorn.

Photo cooperation/Inoue Boring www.ibg.co.jp

POINT

  • Point 1 - There are many things you can notice by understanding engine structure and piston movement.
  • Point 2 - If you like engine maintenance and tuning, you want to own a port grinder, rheater, and various polishing bars
  • .

The cylinder of a 4-stroke engine is a simple cylinder shape, and the intake and exhaust of the air mixture is done by dedicated intake and exhaust valves. In contrast, in a 2-stroke engine, the air mixture enters and exits through various ports on the cylinder wall. This is exactly why the 2-stroke engine has various ports (holes) on the cylinder wall. The piston and piston rings slide over the port holes in such a continuous reciprocating motion, so naturally they are susceptible to damage. In particular, a part of the piston or piston ring may get caught on the edges of the various ports (strictly speaking, it may become "stuck"), and in the worst case scenario, this can lead to seizure or ductility. Chamfering of various ports is a measure to avoid such problems in advance. iB Inoue Boring, where the photo was taken, also manufactures sleeves for intake and exhaust ports with a pillar in the center of the port to prevent the piston from swiveling. The 2-stroke engine is an endangered species, but in order to keep it running in good condition, it is necessary to prevent scratches on the cylinder's inner wall. One way to achieve this goal is to "chamfer" the edges of the various ports. Ideally, the chamfering should be done before the final honing operation. When requesting oversize piston machining from an internal combustion equipment supplier, it is best to request chamfering at the same time. Go to  (9)

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