Should the top of the cylinder sleeve....

[coreyflipp]

.....be flush with the deck of the cylinder? I had a cylinder resleeved and the sleeve is approx. 1mm higher than the deck, enough to feel and even see. The machine shop said they have done numerous resleeves and many have been like that. It doesn't seem right to me.

The only thing I can think is the aluminum expands when hot and takes up the slack.

Does anybody know if this is right?

[honda400ex2003]

that sounds correct from what i remember from mine. steve

[togup]

it depends on the machinist or builder some put the sleeve in and face the top of the jug to ensure its flush and to correct any burs or warpage but alot of builders prefer the sleeve about .001 higher because they believe it helps the seal between the jug and the head making the head gasket crush into it.

[coreyflipp]

Originally posted by togup
it depends on the machinist or builder some put the sleeve in and face the top of the jug to ensure its flush and to correct any burs or warpage but alot of builders prefer the sleeve about .001 higher because they believe it helps the seal between the jug and the head making the head gasket crush into it.

Well, this shop definitely isn't a big powersports builder, and the guy couldn't give a real good answer, but he did say that it would help create that crush seal you talk about. He said he put it in as far as it would go. I just want it however Honda built it.

[togup]

i wouldnt put it together until i contacted a pro builder or the sleeve manufacturer, 1mm sounds excessive .

[flyboy1294]

Originally posted by togup
i wouldnt put it together until i contacted a pro builder or the sleeve manufacturer, 1mm sounds excessive .
I'm with this guy. My sleeve is totally flush, and I have never blown a head gasket. (Might I add that I'm running 12.5:1 compression and a 89mm piston. So if it was going to go, it would go.)

[coreyflipp]

Originally posted by flyboy1294
I'm with this guy. My sleeve is totally flush, and I have never blown a head gasket. (Might I add that I'm running 12.5:1 compression and a 89mm piston. So if it was going to go, it would go.)

Yeah, I've never paid much attention to them, but this caught my eye immediatley, and I can't remember if it's how it's supposed to be or not. I'm going to seek professional help, and I'm going to try to contact an engine builder also.

[honda400ex2003]

let us know what you find. seems like there are many methods to how different builders do it. if possible get an exact measurement before you call someone about it. not to sound harsh but 1mm is quite a bit to guess at and would have to be verified to not sound nuts. most builders would require an actual measurement anyway to even think about helping you. especially since you did not have it done there. im curious to find out :D steve

[coreyflipp]

Ok, so I just talked to a guy at xrsonly, and he said it should be flush. He said it's either not pressed in all the way, or they didn't machine it. He said you can't just put it in and go.

So, I'm gonna take the studs out and have them mill it flush.

[honda400ex2003]

good to know... must be quite an amount sticking up. did you ever get an exact measurement by chance? steve

[coreyflipp]

No dude, I'll try to get a good pic of it and post it up.

[400man]

I bought a cylinder off ebay and when I got it, I noticed the top of the cylinder and sleeve were not flush, mine is sticking up 1.45mm after measuring it with some digital calipers. the guy said it wasnt like this when he shipped it, so is there a chance maybe it was dropped and the sleeve pushed up out of the cylinder?

http://i417.photobucket.com/albums/pp255/ky2stroker/400excylinder004.jpg
http://i417.photobucket.com/albums/pp255/ky2stroker/400excylinder002.jpg
http://i417.photobucket.com/albums/pp255/ky2stroker/400excylinder001.jpg
http://i417.photobucket.com/albums/pp255/ky2stroker/400excylinder005.jpg

[CJM]

No way it moved without intense heat, send it back.

[yellow416ex]

I re-sleeved one myself at home, and they definitely don't move without plenty of heat. As for the top of the sleeve, it has to be exatlcy flush with the top of the jug, otherwise the gasket won't seal around the area where the cam chain is.