Any piston installation tricks?

[wera racer]

I've got less than two weeks before the WERA race at Barber and I just spent big on top end work for my 78 GS1000 (porting, HD springs, overbore to 71mm, new pistons/rings). While installing the cylinders I caught an edge on the #3 oil ring lower rail and didn't know it until the bore was damaged.

I've got a new oil ring on the way and the machinest will bore a spare sleeve I had and I'll try this all over again later this week.

Are there any tricks to installing the pistons/rings in the bores? I've done a couple searches and I've tried everything I can think of, including zip ties, a ring tool, etc. and doing it by hand still seems to be the best technique.

Many thanks!
Rick

 

[Flyboy]

Yes, don't break a ring....
Seriously, some people like to use hose clamps, and various ring squeezers, which I guess is great and can be a big help when you alone, but, like you, I prefer to do it by hand, the biggest help is a buddy with a spare set of hands to help out.
That way you have four hands and four eyes on the job, makes it much easier and you can call no joy before things go pear shaped and back off and try again, it is damn difficult to have your eyes on everything, but a pair on either side of the motor is much better.

 

[gsryder]

Have you machinist chamfer the bottom of the cylinders if he cannot do it look up the name John Pearson, Pearson Racing. He is in Ohio. Mine went together easy peasy.

 

[Steve]

I just had some work done on my wife's bike at Pearson's.

Great guy to work with and very reasonable prices. We had discussed some options which included boring out her cylinders, then he insisted on chamfering the bottoms and gave me a price. I don't remember exactly what it was, but I do remember that it was relatively cheap.

.

 

[sharpy]

Grab/make a pair of pistons supports that slide under #2 and #3 pistons while your trying to assemble. 5mm thick alloy u-shaped supports that slide either side of the conrod and sits on the case and they hold the piston rightangles to the bore. Top of my head there about 60mm wide and 130mm long with a cutout for the conrod. Have you a tried a dry pre-assembly with no rings to see if everything misses if you are using big cams? And think of cleaning everything, then clean it again when putting it together. My boss makes me use some superglue to hold the teardrop barrel o-rings in place and a smear some of your favourite gasket goo around the oil galleries and cam chain tunnel would be ok. Put just a light smear oil oil on the bottom of the barrels when putting together. The bore WILL be coated when you hand turn the engine over to cheack clearance.

 

[wera racer]

Thanks, guys, this is most helpful. I will fab some supports under the pistons and give it another try. Many thanks!

 

[hampshirehog]

Inch (or it might be inch and a quarter - I can't remember) plastic drain pipe cut in to 4 inch long lengths are a perfect fit for the piston supports as well. It's the slightly flexible stuff you want so it squeezes in against the studs.

 

[Smokinapankake]

I used zip ties, a couple short sections of 2x2 dimensional lumber, and a friend. We had it together in about 45 mins. Good luck.

 

[SqDancerLynn1]

3 piece oil ring make sure to install the center expander first Then the thin rings. Make sure it turns freely. Install !!