suggestions required on piston/ring installation on overbored (1166). No champher left, broken ring on attempted installation. What is the usual procedure. Tricks? thank you.
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I've used wide zip ties with good results before. -
Radiator hose clamp of the appropriate diameter.
Oil the rings well, don't tighten the clamp so tight that it won't slide.
Use a cordless drill to turn the screw on the clamp to avoid cramps in your wrist.
Use wood blocks under the two pistons you are working with to prevent the crank from turning.
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mine: 2000 Honda GoldWing GL1500SE and 1980 GS850G'K' "Junior"
hers: 1982 GS850GL - "Angel" and 1969 Suzuki T250 Scrambler
#1 son: 1986 Yamaha Venture Royale 1300 and 1982 GS650GL "Rat Bagger"
#2 son: 1980 GS1000G
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block of wood
Now you mention thatUse wood blocks under the two pistons you are working with to prevent the crank from turning.
. That is too easy 
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The Weisco 1166 rings are a little stiffer than OEM, but I saw Rapid Ray drop a cylinder onto a set of postion in about 15 minutes with bare hands (engine on a bench).
total 2 1/2 hours and the complete top end was bolted torqued and degreed. I was slowing him cleaning parts.
Bill and I took about one tense hour doing it weekend before last on the bike. Used Hose clamps, tight but not too tight. Rocking doesnt help, cylinder straight down.Comment
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You can re-chamfer the bottom of the cylinders to make it easier on yourself. I do it all the time if the machine shop is busy. A GOOD shop will do it before they give you the block back. If it is an automotive machine shop make sure you tell them to chamfer the BOTTOM of the sleeves as they are used to doing the TOPS on automotive blocks! Ray.Comment
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This photo was posted by Renobruce in his beast thread. Very ingenious idea I think; cylinder is suspended using a rope and bungy cord which allows the cylinder to be lowered in a controlled manner. I'm going to try something similar when the time comes on my engine.
Ed
To measure is to know.
Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182
Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846
Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf
KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-ResurrectionComment
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I use these clamps from Pit Posse. You need to buy two sets of them. Use them on the inner two pistons (with the wood block under the pistons) and then move them to the outer pistons. Unlike automotive clamps, you can get these off the pistons after the rings enter the bottom of the cylinders.
Tracy
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