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procedure / hints for installing cylinders on GS1000 ?

exdirtbiker

exdirtbiker

Forum Mentor
Has anyone posted a "how-to" for installing cylinders?
how many hands are required?
spring compressors or fingernails?
I had read some in the past, but when I used "search" I came up empty.

Thanks
Pete
 
Have a machinists put a chamfer on the bottom edge and they will go in easy with a little help from your fingers
 
I've found the service manuals idea of making 2 wooden dowels/supports and my fingers works well.
 
I used two 60-80 mm hose clamps and two 30mm wide strips from a plastic paint bucket. Wrap the strips around the two inner and snug up with the clamps. Put the two middle pistons at top, lower the barrel and it practically walked on. Transfer the strips and clamps to the outer pistons, lower the barrel a bit and then by lowering more and or rotating the crank the outers slide in.
I tried for an hour using fingers and the hose clamps alone but it just didn't feel right. I had help from a second pair of hands to lower the barrel square getting the middle two in.
Others have used peanut butter tubs which would have been better as it would be closer to the piston size than a two gallon bucket. It was a bit tricky getting the strips out from the outer pair without snagging the base gasket ( don't forget it ) as the strips sprang back to normal shape.
 
Keeping the pistons square on is key to making the job easy. I always do the 2 inner first and use plastic pipe wedged under the pistons and resting on the top of the crankcase. For a GS1000, standard sanitary drain pipe (I think it's inch and a quarter but might be wrong) fits perfectly. For entering the rings in to the bores I use a couple of lolly sticks and very gently tap down on the cylinder.
 
For the record, I purchased pipe clamp things, but never opened the wrapper. I used fingernails and a helper to git 'er done.
 
The biggest danger is losing your patience and forcing something. The rings will go in without compressors as long as the chamfer is still on the bottom of the sleeve and the piston is square to the bore. A medium thumping with a fist on top of the cylinders should be all the force required.
 
Dogma said:
The biggest danger is losing your patience and forcing something. The rings will go in without compressors as long as the chamfer is still on the bottom of the sleeve and the piston is square to the bore. A medium thumping with a fist on top of the cylinders should be all the force required.
Click to expand...

Just curious, how many PSI is a medium thump? JK ;)
 
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