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Reassembly Woes: Stuck pistons

  • Thread starter Thread starter ameen
  • Start date Start date
A

ameen

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

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



...yeah, im a dumbass
 
Last edited:
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.
 
Suzuki mad said:
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.
Click to expand...

I tried that. How much force is too much?
 
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.
 
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
 
You probably scratched your cylinder walls. A new cylinder may be in order or oversize pistons.
Sorry to say.
 
Chef wrote: "You probably scratched your cylinder walls"
I think that you are trying to be kind, I was thinking more like gouged.
Over-bore or cylinders, imminent. :(

Eric
 
Most motor reconditioners/machine shops are used to doing car motors so ignore the lead in tapers at the bottom of the bores.
I find it pays to clean up this taper with a fine half round file and remove the acute edge left by the boring job.
Ten minutes spent here can save a lot of grief later

Greg T
 
Very unfortunate, but I know someone who did it 4 times in a row! He bent a few oil ring scrapers every time. The only way those pistons are going to come out is by carfully tappng them with a piece of wood and a hammer and with some wood under the cylinders.
The chances are good that you have damaged the pistons, rings and the cylinders. Inspect them carefully.
My sympathies!
 
oh damn.....thats what i was worried about.. This has turned in to a two month rebuild process. Well when and if i can get it out, i am not sure i want to sink any more money into it. Ebay may be seeing a lot of gs550 parts real soon.

I will get some pictures tonight. FML.
 
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