Getting pistons back into cylinders!

[Max Preload]

Tried putting the pistons in the block and installing like that, no go, far too little room to work. So installed the pistons on the conrods and lowered the block down, 2 pistons at a time (inside first) with a bit of help from fingernails and a flat, thin bit of metal. Even did it all on my own without an adult helping

I fail to see how that can be the case. The gudgeon pin is below the oil ring assembly. With the oil rings just inside the bore, the gudgeon hole is still below the skirt of the liner.

[cbfb]

I fail to see how that can be the case. The gudgeon pin is below the oil ring assembly. With the oil rings just inside the bore, the gudgeon hole is still below the skirt of the liner.

I won't argue with you, cause it sounds like you know a lot more than I do, but because of the chamfer at the bottom of the cylinder, I found that with the gudgeon hole beneath the liner, there was enough room for the 2nd ring to come unstuck in the chamfer and make it tricky to get back in. So I found it easier to put the pistons on the conrods first. But I can see your point, it looked like it should work but I just wasn't dextrous enough.

[Max Preload]

I won't argue with you, cause it sounds like you know a lot more than I do, but because of the chamfer at the bottom of the cylinder, I found that with the gudgeon hole beneath the liner, there was enough room for the 2nd ring to come unstuck in the chamfer and make it tricky to get back in. So I found it easier to put the pistons on the conrods first. But I can see your point, it looked like it should work but I just wasn't dextrous enough.

Ah right. It must be quite a long lead in! But why didn't you use your other 3 pair of hands?

Had I found myself in that situation I'd have combined the two methods. Pistons in the bore up to the oil ring and then the gudgeon then the oil rings.

Piston rings are quite delicate. You should have probably used plastic rather than metal when pushing them in though.

[cbfb]

Ah right. It must be quite a long lead in! But why didn't you use your other 3 pair of hands?

Had I found myself in that situation I'd have combined the two methods. Pistons in the bore up to the oil ring and then the gudgeon then the oil rings.

Piston rings are quite delicate. You should have probably used plastic rather than metal when pushing them in though.

lol, yeah octopuses would make awesome mechanics.

Point noted, will use plastic next time. Hopefully won't have damaged them, didn't have to use much force at all, just a flick to get them in place.

[disorderly]

I worked on alot of 4 cylinder bikes doing top end recos etc... it is possible to use your hands while a 2nd pair of hands hold the barrels
1. make sure you put base gasket ,dowels and any o rings that may go on the base as its a pain to take the barrels off a 2nd time.
2. oil rings making sure the ring gaps are staggered (make sure ring ends are opposite sides of each other)
3. I start with no 1 and 4 pistons rotate so they are at 12.o clock, 2nd person lowers barrels over studs now squeeze top rings of both pistons with fingers and work top of piston into barrel while 2nd person lowers gently still holding most of the weight of barrel a gentle tap with a rubber hammer downwards, repeat with 2nd piston ring. the oil rings are not so bad but make sure that the upper and lower oil rings DONT overlap they touch end to end ( hope that makes sense )
4. rotate and repeat with 2 centre pistons these are tricky due to tight space but it can be done just remember this is not a brute force job it can be very easy to break a ring if your not careful
I worked in a motorcycle dismantlers for 10 yrs and performed this many times i hope this is of some help just take your time and good on ya for giving it a go I think the more you do work on your own bike the more you learn the more confidence you get and its all good !!

[cbfb]

I worked on alot of 4 cylinder bikes doing top end recos etc... it is possible to use your hands while a 2nd pair of hands hold the barrels
1. make sure you put base gasket ,dowels and any o rings that may go on the base as its a pain to take the barrels off a 2nd time.
2. oil rings making sure the ring gaps are staggered (make sure ring ends are opposite sides of each other)
3. I start with no 1 and 4 pistons rotate so they are at 12.o clock, 2nd person lowers barrels over studs now squeeze top rings of both pistons with fingers and work top of piston into barrel while 2nd person lowers gently still holding most of the weight of barrel a gentle tap with a rubber hammer downwards, repeat with 2nd piston ring. the oil rings are not so bad but make sure that the upper and lower oil rings DONT overlap they touch end to end ( hope that makes sense )
4. rotate and repeat with 2 centre pistons these are tricky due to tight space but it can be done just remember this is not a brute force job it can be very easy to break a ring if your not careful
I worked in a motorcycle dismantlers for 10 yrs and performed this many times i hope this is of some help just take your time and good on ya for giving it a go I think the more you do work on your own bike the more you learn the more confidence you get and its all good !!

Well, I see where you're coming from, I very gently pushed the rings up gently gthrough through the cylinders. All good, pushed up AOK.

Cha

C

[cbfb]

Fingered

Really that far fingerered?

[cbfb]

A ! As described above, cool to everyone who slaggs off process butts ass