Reassembly Woes: Stuck pistons

[ameen]

Well I started off very excited, about to reassemble my engine and get back to riding. First I ripped my base basket. Ordered another one and was ready to go. This time, I manage to try to get the pistons in with out a proper ring compressor.
Well, I thought I could pull it off but it didn't work so well. The pistons didn't slide in very easily. Being my first time doing this, I forced them a little. Well that brings me up to now. Pistons 2 and 3 would not go in all the way and now I cannot remove them either. 1 and 4 easily went in and back out. What should I do at this point? I am kind of in a bind.


Thank You

[propflux01]

First I would try very gently, and with a wooden block, to try and tap them back out. put oil in the top of the cylinders to help aid. Not knowing the nature of the machine work done or size of pistons, etc, this would be my advice on it to try first.

[ameen]

Already tried that. They are securely stuck. Oh and it is on a 1982 GS550

Thanks

[teet]

Hmmm..not good. Ive never had this problem on a bike, but on some old Kohler engines in the past Ive had some situations where it was really tight sliding the piston in..even with a compressor. I later discovered that I received the wrong rings, and they were .010 oversize, when I needed std size. I re honed the "cast iron" bore, and no problems installing the correct size....

I would probably oil the heck out of the cylinder, and try to gently tap them out with a piece of wood or a dowel, maybe some heat??

Someone else has bound to have down this road before, and can offer some advice...

Good luck

Jeff (teet)

EDIT....Just read the other replies, and your "securely stuck" statement..how bout a engine builder, or machine shop close by? Then buy ring compressors for the next time.

[Nessism]

Most likely the rings did not go into the grooves on the piston and now you have damaged the rings. Only thing to do is carefully remove the cylinder, using force as necessary, and carefully inspect the rings, cylinder, and pistons for damage.

When you install the cylinder it really helps to have someone that can help. You have to carefully compress the rings into the grooves on the pistons before you stick the piston inside the cylinder.

Good luck and hope the rings are not damaged.

[posplayr]

somebody RING

http://www.thegsresources.com/_forum/showpost.php?p=836974&postcount=46

[chef1366]

Bent ring.
Start over.

[gearhead13]

somebody RING

http://www.thegsresources.com/_forum...4&postcount=46

Exactly what i was thinking

[ameen]

somebody RING

http://www.thegsresources.com/_forum...4&postcount=46

how did you get the jugs off?

[gearhead13]

how did you get the jugs off?

My question is how did you get them on if its that hard to take off?
They should slide in nice, without much force.

[ameen]

I kind of tried to force them in a little. Live and learn i guess.



...yeah, im a dumbass

[Suzuki mad]

You can use the crank to get them out.

Firstly block the barrel up as high as it will go. Then using the 19mm nut on the points cover end of the crank gently turn clock wise and anti clock wise to draw the middle two pistons out.

DON'T FORCE IT.

[ameen]

You can use the crank to get them out.

Firstly block the barrel up as high as it will go. Then using the 19mm nut on the points cover end of the crank gently turn clock wise and anti clock wise to draw the middle two pistons out.

DON'T FORCE IT.

I tried that. How much force is too much?

[Suzuki mad]

They should slide out quiet easily so normal 1/2inch drive and arm strength is enough to shift them.

If your having to put full body weight or and extension then thats too much.

You don't want the pistons to come out and spin the crank which could damage the cog on the crank and cam chain.

[67fire]

Can you post any pictures of the current condition so that we may come up with more ideas that will not damage anything else?

Eric