How far down the rabbit hole will I go... `78 GS750

[SOCKinside]

hang in there!, your more than half way there...

[bottobot]

http://www.youtube.com/watch?v=gBoCaVlxhCI

Now that is motivating

I'm hitting a wall with trying to install the cylinders over the piston rings. I've done it before with help from a friend where we basically each do a side in unison. But on my own without a proper ring compressor tool I'm finding it impossible. I've tried using large hose clamps to keep the rings compressed while having cylinders 2 and 3 at TDC. But when I set the cylinder down and it pushed the hose clamps down past the first ring the rings just pop out and don't go in the cylinder. I tried doing it by hand for awhile too, but no go there as well.

Going to regroup and start putting the valves together while I think about another solution. Any tips?

[Big T]

Now that is motivating

I'm hitting a wall with trying to install the cylinders over the piston rings. I've done it before with help from a friend where we basically each do a side in unison. But on my own without a proper ring compressor tool I'm finding it impossible. I've tried using large hose clamps to keep the rings compressed while having cylinders 2 and 3 at TDC. But when I set the cylinder down and it pushed the hose clamps down past the first ring the rings just pop out and don't go in the cylinder. I tried doing it by hand for awhile too, but no go there as well.

Going to regroup and start putting the valves together while I think about another solution. Any tips?

To use the hose clamps, they must be at the exact proper tension, which is where you can just move them by hand when they're over the rings. also,oil the rings and piston lightly

Otherwise, the weight of the cylinder block pushes one clamp down and you're cockeyed and have to start over

Another trick is to use some 2X lumber to prop up the cyllinder and raise the pistons into it and let the house clamps slide down

[bottobot]

To use the hose clamps, they must be at the exact proper tension, which is where you can just move them by hand when they're over the rings. also,oil the rings and piston lightly

Otherwise, the weight of the cylinder block pushes one clamp down and you're cockeyed and have to start over

Another trick is to use some 2X lumber to prop up the cyllinder and raise the pistons into it and let the house clamps slide down

I see what you mean, I spent about an hour messing around with different ways to do it and I just couldn't so I broke down and bought a proper ring compressor tool for motorcycles. Its sort of like a pair of pliers with a ring you can squeeze.

I tore the base gasket anyways so I'm gonna tackle that whole thing when I get the tool and the gasket in the mail.

In the meantime I put together my valves. Here is a pic with the first one having been put in.

[bottobot]

Finally some more progress. Been waiting for various parts to come in. Like an exhaust valve from Eric. Thanks dude it worked out great! Also a base gasket since I tore my other one taking it out. Now I get to put the cylinders back on. Man is it tough to do on your own.

I've got it up to the point you see now. I can't get past the second piston ring on pistons 2 and 3. So I will wait for my special ring compressor tool to show up, or I can get a friend to spend some time helping me do this. Here is a pic of the progress. Oh and other good news is that my cylinder head is all back together valves in and ready to go.

[MisterCinders]

Did you test the head for leaks? Pour some acetone into the intakes and wait a bit. Then see if any seeped past the valves.

[Chuck78]

Well how did this project end up?
I may open up my engine by spring and see what "the p.o. bored the motor out" meant by the guy I got it from. May have a Wiseco 844 kit (it's really fast, kept up quite well with an 1132cc KZ1000 on a Hocking Hills State Forest MC trip a few weeks ago).
I lucked out and contacted MTC Engineering to find that they had ONE KIT LEFT hiding in their warehouse of the old GS750/850 big bore kits, so I have some 850 jugs @ 69mm that need to go to a worthy machine shop to be bored for these 72mm pistons! Had them machine them down so I can run 87 Octane in the summer heat, they said just under 10:1 after shaving .040" off the tops from 10.5:1 previously.

Had you gotten a head gasket from Cometic? I had completely forgotten that I would possibly need a custom head gasket when running 850 cylinders with +3mm oversized pistons. You may have been able to do a stock 850 gasket if it fits the 750 cylinder block fine.

[TeamDar]

Use a stock GS1100G shaft drive head gasket. It is 72mm and will fit perfect.