Page 1 of 9

Win Progress Co.,Ltd(Pharkant Branch)

Engine Overhauling Check Sheet

Customer
JO8CV Crankshaft M/C Model S/N
Check Sheet Engine Model S/N
Disassembly WH Date
Assembly Reference Service Report No.
Unit=mm
Item Check Point STD Limit Actual Clearance
A
Diameter 80 79.98
1 B
Ovality(A-B) 0.01
A
Diameter 80 79.98
2 B
Ovality(A-B) 0.01
A
Diameter 80 79.98
3 B
Ovality(A-B) 0.01
A
Main Bearing Diameter 80 79.98
4 B
Journal
Ovality(A-B) 0.01
A
Diameter 80 79.98
5 B
Ovality(A-B) 0.01
A
Diameter 80 79.98
6 B
Ovality(A-B) 0.01
A
Diameter 80 79.98
7 B
Ovality(A-B) 0.01
A
Diameter 65 64.98
1 B
Ovality(A-B) 0.01
A
Diameter 65 64.98
2 B
Ovality(A-B) 0.01
A
Diameter 65 64.98
3 B
Connecting Ovality(A-B) 0.01
Bearing Journal A
Diameter 65 64.98
4 B
Ovality(A-B) 0.01
A
Diameter 65 64.98
5 B
Ovality(A-B) 0.01
A
Diameter 65 64.98
6 B
Ovality(A-B) 0.01
Center Journal STD 36 37
Width Over Size
Defection at center 0.15 0.15
Thrust bearing thickness 2.5 2.45-2.55
End play of crankshaft 0.05-0.239 0.5

Timing Gear Reused Remark:

Condition Replaced
Front Remark:
Oil Seal Seat
Condition Rear

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Page 2 of 9

Win Progress Co.,Ltd(Pharkant Branch)

Engine Overhauling Check Sheet

Customer
JO8CV Connecting Rod M/C Model S/N
Check Sheet Customer Model S/N
Disassembly WH Date
Assembly Reference Service Report No.
1st 51 Lbf.ft Remark: Make Sure that numerical
Tighting torque for connecting making of connecting rod and bearing
bolts 2nd cap are in same side.
3rd
Unit=mm
Item Check Point STD Limit Actual Clearance
A
1
B
1 65.03 65.08
A
2
B
A
1
B
2 65.03 65.08
A
2
B
A
1
B
3 65.03 65.08
A
2
Big End B
Bearing A
1
B
4 65.03 65.08
A
2
B
A
1
B
5 65.03 65.08
A
2
B
A
1
B
6 65.03 65.08
A
2
B
A
1
B
1 37.015-37.025 37.1
A
2
B
A
1
B
2 37.015-37.025 37.1
A
2
B
A
1
B
3 37.015-37.025 37.1
A
2
Small End B
Bearing A
1
B
4 37.015-37.025 37.1
A
2
B
A
1
B
5 37.015-37.025 37.1
A
2
B
A
1
B
6 37.015-37.025 37.1
A
2
B
Check the connecting rod parallel alignment to all connecting rods.
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Page 2 of 9
Page 3 of 9

Win Progress Co.,Ltd(Pharkant Branch)

Engine Overhauling Check Sheet

Customer
JO8CV Camshaft M/C Model S/N
Check Sheet Customer Model S/N
Disassembly WH Date
Assembly Reference Service Report No.

Tighting torque for camshaft bolts 23 Lbf.ft

Unit=mm
Item Check Point STD Limit Actual Clearance
A
Diameter 40 39.85
1 B
Ovality(A-B) 0.01
A
Diameter 40 39.85
2 B
Ovality(A-B) 0.01
Camshaft A
Diameter 40 39.85
Bearing 3 B
Journal Ovality(A-B) 0.01
A
Diameter 40 39.85
4 B
Ovality(A-B) 0.01
A
Diameter 40 39.85
5 B
Ovality(A-B) 0.01
1
Intake 50.067 49.567
2
1
1
Exhaust 52.104 51.604
2
1
Intake 50.067 49.567
2
2
1
Exhaust 52.104 51.604
2
1
Intake 50.067 49.567
2
3
1
Exhaust 52.104 51.604
2
Cam Height
1
Intake 50.067 49.567
2
4
1
Exhaust 52.104 51.604
2
1
Intake 50.067 49.567
2
5
1
Exhaust 52.104 51.604
2
1
Intake 50.067 49.567
2
6
1
Exhaust 52.104 51.604
2
End Play of Camshaft 0.1-0.178

Camshaft Deflection 0.04 0.1

Reused Remark:
Cam Gear
Replaced
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Page 3 of 9

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Page 4 of 9

Win Progress Co.,Ltd(Pharkant Branch)

Engine Overhauling Check Sheet

Customer
JO8CV Rocker Arm Shaft M/C Model S/N
Check Sheet Customer Model S/N
Disassembly WH Date
Assembly Reference Service Report No.

Tighting Torque for Rocker Arm Shaft bolts 43 Lbf.ft

Unit=mm
Item Check Point STD Limit Actual Clearance
A
Diameter 22 21.92
1 B
Ovality(A-B) 0.01
A
Diameter 22 21.92
2 B
Ovality(A-B) 0.01
A
Diameter 22 21.92
3 B
Ovality(A-B) 0.01
Rocker Arm A
Diameter 22 21.92
Shaft Outer 4 B
Diameter Ovality(A-B) 0.01
A
Diameter 22 21.92
5 B
Ovality(A-B) 0.01
A
Diameter 22 21.92
6 B
Ovality(A-B) 0.01
A
Diameter 22 21.92
7 B
Ovality(A-B) 0.01
A
1 Diameter 22 22.08
B
A
2 Diameter 22 22.08
B
A
3 Diameter 22 22.08
B
Rocker Arm A
Bushing Inner 4 Diameter 22 22.08
Diameter B
A
5 Diameter 22 22.08
B
A
6 Diameter 22 22.08
B
A
7 Diameter 22 22.08
B
End play of rocker arm 0.28-0.82

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Page 4 of 9
Page 5 of 9

Win Progress Co.,Ltd(Pharkant Branch)

Engine Overhauling Check Sheet

Customer
JO8CV Piston M/C Model S/N
Check Sheet Customer Model S/N
Disassembly WH Date
Assembly Reference Service Report No.
Unit =mm
Piston Crown Condition Coment
Piston Scuff Condition Coment
Item Check Point STD Limit Actual Coment
Top 0.3-0.4 1.5
1 2nd 0.3-0.45 1.2
Oil 0.3-0.45 1.2
Top 0.3-0.4 1.5
2 2nd 0.3-0.45 1.2
Oil 0.3-0.45 1.2
Top 0.3-0.4 1.5
3 2nd 0.3-0.45 1.2
Oil 0.3-0.45 1.2
Ring Gap
Top 0.3-0.4 1.5
4 2nd 0.3-0.45 1.2
Oil 0.3-0.45 1.2
Top 0.3-0.4 1.5
5 2nd 0.3-0.45 1.2
Oil 0.3-0.45 1.2
Top 0.3-0.4 1.5
6 2nd 0.3-0.45 1.2
Oil 0.3-0.45 1.2
Piston Ring
Top 2.58-2.6 2.7
1 2nd 2.06-2.08 2.2
Oil 4.01-4.03 4.1
Top 2.58-2.6 2.7
2 2nd 2.06-2.08 2.2
Oil 4.01-4.03 4.1
Top 2.58-2.6 2.7
3 2nd 2.06-2.08 2.2
Oil 4.01-4.03 4.1
Ring Clearance
Top 2.58-2.6 2.7
4 2nd 2.06-2.08 2.2
Oil 4.01-4.03 4.1
Top 2.58-2.6 2.7
5 2nd 2.06-2.08 2.2
Oil 4.01-4.03 4.1
Top 2.58-2.6 2.7
6 2nd 2.06-2.08 2.2
Oil 4.01-4.03 4.1
Item Check Point STD Limit Actual Codition
1 36.989-37 36.96
2 36.989-37 36.96
3 36.989-37 36.96
Piston Pin Pin Diameter
4 36.989-37 36.96
5 36.989-37 36.96
6 36.989-37 36.96
The piston ring opening must be 180 degree to each other. Make sure the correct upper and button side of piston
ring. Refer service manual for more detail.

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Page 5 of 9

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Page 6 of 9

Win Progress Co.,Ltd(Pharkant Branch)

Engine Overhauling Check Sheet

Customer
JO8CV Cylinder Block M/C Model S/N
Check Sheet Customer Model S/N
Disassembly WH Date
Assembly Reference Service Report No.

Unit=mm
Description Status Comment
Clean the cylinder block carefully. finished
Check the cylinder block for crack ,damage,worn, etc Reuse Repair Replace
Check the flatness of upper surface(cylinder head side) Reuse Repair Replace
Check the flatness of lower surface(oil sump side) Reuse Repair Replace

Item Check Point STD Limit Plane Point 1 Point 2

A
1 80.03-80.1 80.15
B
A
2 80.03-80.1 80.15
B
A
3 80.03-80.1 80.15
B
A
4 80.03-80.1 80.15
B
A
5 80.03-80.1 80.15
B
A
6 80.03-80.1 80.15
B

Piston cooling noozle

condition check No.1 No.2 No.3 No.4 No.5 No.6 Comment
(OK/NOK)

Item Check Point STD Limit Actual

1 8 8.04
Condition Checking

2 8 8.04
Condition Checking
Depth 8 8.04
Cylinder (Check 8 3
Condition Checking
Liner Collar pointds to
from Block each 4 8 8.04
cylinder) Condition Checking
8 8.04
5
Condition Checking

6 8 8.04
Condition Checking
1 8.08 8.01
Cylinder 2 8.08 8.01
Check 8
Liner 3 8.08 8.01
points to
Sealing
each 4 8.08 8.01
Surface
from block cylinder
5 8.08 8.01
6 8.08 8.01
Flatness of upper surface
(Cylinder head size) 0.05 0.2
Page 6 of 9

Win Progress Co.,Ltd(Pharkant Branch)

Engine Overhauling Check Sheet

Customer
JO8CV Cylinder Block M/C Model S/N
Check Sheet Customer Model S/N
Disassembly WH Date
Assembly Reference Service Report No.

Unit=mm

STD Limit Plane Upper Middle Lower

A
1 114 114.15
B
A
2 114 114.15
B
A
3 114 114.15
Inner Bore B
Diameter A
4 114 114.15
B
Cylinder A
5 114 114.15
liner B
A
6 114 114.15
B
1 8.08 8.01
2 8.08 8.01
Higher of
Liner collar 3 8.08 8.01
(Measure in 4 8.08 8.01
4 points)
5 8.08 8.01
6 8.08 8.01
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Page 8 of 9

Win Progress Co.,Ltd(Pharkant Branch)

Engine Overhauling Check Sheet

Customer
JO8CV Cylinder Head M/C Model S/N
Check Sheet Customer Model S/N
Disassembly WH Date
Assembly Reference Service Report No.
Unit=mm
Note: Check the valve stem for bending , abnormal ware,etc. If valve stem is bent or valve is worn out, discard it.
Item Check Point STD Wear Limit Actual Clearance
Intake 0.023-0.058 0.12
1
Exhaust 0.037-0.067 0.15
Intake 0.023-0.058 0.12
Radial Clearance 2
of Exhaust 0.037-0.067 0.15
Valve Guide Intake 0.023-0.058 0.12
Note 1: Valve 3
Exhaust 0.037-0.067 0.15
seal must be
removed. Intake 0.023-0.058 0.12
4
Note 2: Valve Exhaust 0.037-0.067 0.15
guides are not Intake 0.023-0.058 0.12
replaceable. 5
Exhaust 0.037-0.067 0.15
Intake 0.023-0.058 0.12
6
Exhaust 0.037-0.067 0.15
Check Point STD TOP Middle Middle
Intake 6.92-7
1
Exhaust 6.85-7
Intake 6.92-7
2
Exhaust 6.85-7
Intake 6.92-7
Valve Stem 3
Exhaust 6.85-7
Diameter(A)
Intake 6.92-7
4
Exhaust 6.85-7
Intake 6.92-7
5
Exhaust 6.85-7
Intake 6.92-7
6
Exhaust 6.85-7
Check Point Wear Limit Actual (Measure 3 points)
Intake 2.4
1
Exhaust 2.6
Intake 2.4
2
Exhaust 2.6
Valve Head Intake 2.4
Edge 3
Exhaust 2.6
Thickness(B)
Intake 2.4
4
Exhaust 2.6
Intake 2.4
5
Exhaust 2.6
Intake 2.4
6
Exhaust 2.6
STD Actual (Measure 3 points)
Intake 39-39.016
1
Exhaust 37-37.016
Intake 39-39.016
2
Exhaust 37-37.016
Intake 39-39.016
Valve Head 3
Exhaust 37-37.016
Diameter( C )
Intake 39-39.016
4
Exhaust 37-37.016
Intake 39-39.016
5
 Diameter( C )
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5
Exhaust 37-37.016
Intake 39-39.016
6
Exhaust 37-37.016
STD Limit Actual
Intake 0.55-0.85 1.1
1
Exhaust 1.05-1.35 1.6
Intake 0.55-0.85 1.1
2
Exhaust 1.05-1.35 1.6
The depth of
valves (center) Intake 0.55-0.85 1.1
3
from the cylinder Exhaust 1.05-1.35 1.6
head Intake 0.55-0.85 1.1
sealing surface 4
Exhaust 1.05-1.35 1.6
Intake 0.55-0.85 1.1
5
Exhaust 1.05-1.35 1.6
Intake 0.55-0.85 1.1
6
Exhaust 1.05-1.35 1.6
STD Limit Actual
Intake 75.7 72.7
1
Exhaust 75.7 72.7
Intake 75.7 72.7
2
Exhaust 75.7 72.7
The free length Intake 75.7 72.7
3
of valve spring Exhaust 75.7 72.7
Intake 75.7 72.7
4
Exhaust 75.7 72.7
Intake 75.7 72.7
5
Exhaust 75.7 72.7
Intake 75.7 72.7
6
Exhaust 75.7 72.7
Intake 64.6 61.6
1
Exhaust 64.6 61.6
Intake 64.6 61.6
2
Exhaust 64.6 61.6
The free length Intake 64.6 61.6
3
of valve spring Exhaust 64.6 61.6
(Inner) Intake 64.6 61.6
(Only : JO8CT) 4
Exhaust 64.6 61.6
Intake 64.6 61.6
5
Exhaust 64.6 61.6
Intake 64.6 61.6
6
Exhaust 64.6 61.6
Intake 2.5 2.6
1
Exhaust 2.5 2.6
Intake 2.5 2.6
2
Exhaust 2.5 2.6
Intake 2.5 2.6
The valve 3
Exhaust 2.5 2.6
spring
squareness Intake 2.5 2.6
4
Exhaust 2.5 2.6
Intake 2.5 2.6
5
Exhaust 2.5 2.6
Intake 2.5 2.6
6
Exhaust 2.5 2.6
Check the cylinder head for crack, abnormal wear, etc

Check the cylinder head surface.

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Page 8 of 9

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