1088 installation instructions:
The following instructions are provided as a
supplement to the factory service manual you should
refer to the manual for specific torque values and
procedures.
The 1088cc big bore kit is a drop in big bore piston
and cylinder that will install the same as the original
parts with the exception of the cylinder head gasket.
The head gasket will fit directly between the cylinder
and the cylinder head and is made of copper
therefore it will need to be coated with the sealer
provided. No base gasket is provided with the kit in
order to achieve maximum compression. It is
necessary to use the provided sealer to seal the
cylinder to the engine case.
1.) Wash your cylinder with warm soapy water and dry
with compressed air.
2.) Lightly coat the inside cylinder wall with engine oil
or engine assembly lube (Red Line brand is
recommended.)
3.) Coat the bottom of the cylinder and the engine
case with the sealer provided. Apply a uniform coat
and set aside.
4.) Assemble the piston rings to the piston. Install the
oil control rings first the same as the stock piston
assembly. Next, install the second compression ring
(black) in the second groove; finally install the top
ring (metal finish) in the top groove. Assure that all
rings are oriented on the piston correctly and ring
gaps are positioned 72deg. apart.
5.) It is possible to install the piston in one of two
ways.
Method one:
5a. Compress the piston rings using a suitable ring
compressor.
5b. Install the piston in the bottom of the cylinder by
lightly tapping it with a rubber mallet (BE SURE THE
LARGE INTAKE VALVE POCKETS ARE FACING TOWARD
THE THROTTLE BODIES AND THE EXHAUST POCKETS
ARE FACING THE EXHAUST PIPE)
5c. Install one circlip into the piston and lubricate the
piston pin with engine oil or assembly lube.
5d. Adjust the piston position in the cylinder so that
the piston pin will slide into place, slide the piston
pin back out enough for the connecting rod to be
inserted in the piston.
5e. Lower the cylinder and piston assembly onto the
engine case (be sure not to disturb the piston while
inside the cylinder) slide the piston pin through the
connecting rod until it seats against the circlip (it may
be necessary to lightly tap the pin into place but it
should not be forced) install the remaining circlip
and tap the cylinder assembly into place.
6.) Apply a uniform coating of sealer to both sides of
the head gasket and set aside, coat the top of the
cylinder block and the bottom of the cylinder head
and bolt the head to the cylinder in the same manner
described in the service manual using the same
torque values.
For best results allow the sealer to sit overnite or
about 12 hrs. before running the engine.
Method two: This is the same as described in the
factory service manual.
1.) Assemble the piston with the rings and apply the
sealer as described above.
2.) Assemble the piston and wrist pin to the
connecting rod same as above. See 5b, 5c
3.) Compress the piston rings with a suitable ring
compressor.
4.) Lower the cylinder onto the piston and lightly tap
the cylinder down on top of the piston and down to
mate with the engine case.
5.) Install cylinder head and related hardware and
torque to factory specs.