Broke a ring...ugh!

[Guest]

Well, still trying to put my engine back together -- a project that I started late last spring. Anyway, in trying to slip the cylinder body over the pistons, I actually snapped one of the rings!

I hope I'm not the only person who's done this. I tried using hose clamps to keep the rings in place while I slipped the cylinders over the pistons..it sort of worked but, anyway, things seemed to be going on place nicely and I was feeling like it was coming together. Then I noticed one of the rings wasn't where it was supposed to be.

sure enough, I guess in pushing the cylinder body down I must have used too much force and broke it. I used a magnet to get the half out that had fallen into the engine.

Guess I'm ordering a new set of rings. I'm just glad I have a second bike to ride while I work on this project.

[blowerbike]

2 small screwdrivers and added chamfer to the bottom of the liners will make your life easy.

[JTGS850GL]

2 small screwdrivers and added chamfer to the bottom of the liners will make your life easy.

Can you give a little more detail on the chamfering process? How and how much would be helpful?

I plan on rebuilding my spare GS1000G engine as well and anything that would assist in putting the cylinder jugs back on would be helpful. Not trying to thread jack, but I think it's relative to the conversation.

[azr]

I've never broke on but I did bend one of the oil rings once. I've got installing the pistons and rings down part now. Just cut two pieces of wood as described in the Suzuki manuals. When you start dropping the head over the the two inner pistons you simple have the head at a bit of an angle. The one side of the piston and rings slips right in and then you simply push the other half in with your finger and then rotate the crank a tich moving the pistons up to the next ring, then repeat. The trick is using the crank to move the pistons up NOT pushing the head down.

[jbthomp]

Can you give a little more detail on the chamfering process

Just use a cartridge roll on a dremel and very carefully take the edge off around the bottom of the cylinder on the inside. You don't have to take off much. Just take the sharp edge off. You can use a file too if you don't have a dremel.

[Agemax]

I've never broke on but I did bend one of the oil rings once. I've got installing the pistons and rings down part now. Just cut two pieces of wood as described in the Suzuki manuals. When you start dropping the head over the the two inner pistons you simple have the head at a bit of an angle. The one side of the piston and rings slips right in and then you simply push the other half in with your finger and then rotate the crank a tich moving the pistons up to the next ring, then repeat. The trick is using the crank to move the pistons up NOT pushing the head down.

i usually find pistons work better when inserted into the cylinders rather than into the head!

[oldgsfan]

I've never broke on but I did bend one of the oil rings once. I've got installing the pistons and rings down part now. Just cut two pieces of wood as described in the Suzuki manuals. When you start dropping the head over the the two inner pistons you simple have the head at a bit of an angle. The one side of the piston and rings slips right in and then you simply push the other half in with your finger and then rotate the crank a tich moving the pistons up to the next ring, then repeat. The trick is using the crank to move the pistons up NOT pushing the head down.

Thanks.. I'll try this. It'll be a few days before I get the new rings.

[blowerbike]

Just use a cartridge roll on a dremel and very carefully take the edge off around the bottom of the cylinder on the inside. You don't have to take off much. Just take the sharp edge off. You can use a file too if you don't have a dremel.

do as he says and life will be good.
some cylinders i have installed literately fell on each pair of pistons.
the more leading edge the better but careful nut to cut off your fingers when installing....

[JTGS850GL]

Good tip. Thanks!