Installing Cylinder Question

[johnod]

Whats the trick for sliding cylinder down over pistons?

What position should pistons be in, how many am I trying to get in at a time, and so on?

Thanks

[Steve]

Is this on the Ultra Classic or the K1200?

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[johnod]

Is this on the Ultra Classic or the K1200?

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Well seeing as this is a GS forum, lets go with the GS1000S.

[Steve]

Yeah, even though it is a GS forum, there are many here that can provide in-depth details on most of the bikes in your signature.

OK, now for the GS discussion:

My Clymer manual has a picture of a device you can make to help install the cylinders. Think of it as a tuning fork without a handle. Dimensions will vary a bit from bike to bike, but it's basically a piece of 1/2" plywood that is about 8 inches long and narrow enough to fit between the cylinder studs, about 2 1/2" or so. Cut a slot down the middle that will slide past the connecting rod. Make two of these.

Rotate the crank so #2 and #3 pistons are UP. Make sure the base gasket is in place, along with any other spacers and o-rings. Slide the plywood forks into place from the front, rotate the crank just a bit until the pistons hold the forks in place. Make sure the ring gaps are properly positioned, set the cylinders over the pistons. Using your fingers, you can push the top ring into the bottom of one of the cylinders. Move to the other side, do the top and second rings on the other piston. Move back to the first side, do the second ring and the oil rings. Finally, go back to the other side, squeeze the oil rings into the cylinder. Wiggle the cylinders down a bit.

Rotate the crank to release the grip on the forks, then rotate it to bring pistons 2 and 3 down, while 1 and 4 come up to meet the cylinders. Continue by alternating sides to get the rings into the cylinders.

Somehere in the process, you should fish the cam chain up through the tunnel. Finish sliding the cylinders down the pistons and bring the cam chain to a place where you can anchor it. (I use a short length of stiff wire, like a coat hanger to hold the chain.) Put the head gasket in place, set the head on top and bolt everything down and torque it.

The process works a little bit quicker if you have a knowledgeable helper, but it's easily-enough done by yourself.

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[johnod]

Perfect, thanks, that should do it.
I'll round up a helper too.

[Steve]

I found a picture that I had saved from the manual. Hope it helps a bit.
I made mine longer for easier handling.



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[johnod]

Excellent thanks again.

[Steve]

Kinda figured somebody would produce something along that line.

I guess it comes down to deciding whether you have the money or the plywood already at-hand.

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