Mitsubishi — Replacing cylinder sleeve
Repair & overhaul
From a Mitsubishi service manual — check it applies to your exact model before use.
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Procedure
- Set up a boring machine on the crankcase aligned with center of the less-worn area of the sleeve at the bottom.
- Bore the sleeve until its stock thickness is about 0.5 mm (0.020 in.).
- Break and remove the sleeve, being careful not to damage the inside surface of the crankcase.
- Use cylinder sleeve installer (34291-00200) to install a replacement sleeve.
- Press sleeve into crankcase leaving a protrusion of 0.3 to 0.5 mm (0.012 to 0.020 in.) at the top; make flush with crankcase top.
- Bore and hone the sleeve to 102 +0.045 mm (4.02 in.) diameter.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Inside diameter of cylinder sleeve: 102.010 - 102.045 mm; service limit 102.700 mm
- Hone oversize +0.25 mm (0.0098 in.) or +0.5 mm (0.0197 in.)
Source: Mitsubishi service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.