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Reassembly Woes: Stuck pistons

  • Thread starter Thread starter ameen
  • Start date Start date
I read through all the pages of this & I think I may know why you had this problem. Anytime you put new rings on used pistons, you HAVE to clean the ring grooves in the pistons before you put the new rings on them. Carbon builds up in the ring grooves, behind the old rings, & if you don't remove this carbon before installing the new rings, the new rings won't be allowed to compress far enough in the cylinder to fit the bore correctly. I believe this could be why your pistons were stuck so tightly. You also should stick the new rings into each cylinder to make sure the ring end gaps are large enough. Also, never hit parts inside your motor with anything but WOOD or a plastic like nylon. One last thing, NEVER hit the skirts of a piston if they look cockeyed. If you colapse the skirt even a couple of THOUSANDTHS of an inch it will be junk. Ray.
 
I got them out. Beat the hell out of the piston

Surprisingly, the cylinders are still fine. Turns out that it was the one oil ring on piston 2.

Rapidray, i think you are right about cleaning the grooves, i don't think i did a very good job. Any recommendations of a good method?


on a side note does anyone know what this part is? I found it on the floor by my bike while i was rebuilding the engine. Honestly i am not sure if it even from the bike or not. If nobody knows, ill put it in its own thread.



Thanks again, you guys are great!
 
nice, good thing i came across that. Damn, that gets me to thinking, i hope there are not any other small pieces that lost...

First time building an engine is always an adventure.
 
Yeah, I lost that piece myself and the spring that goes with it. They were about $1 each from my local Zook dealer. They kept using the same plunger up until 2004 or 2005 on some bikes IIRC. Loss of the gear indicator is not such a big deal to me, but it's really nice knowing when I'm in neutral :eek:

There shouldn't be too many surprises like that.
 
Update: so i got the pistons in. Noticed something new though. The nubs on the end of the crankshaft are broken
:(

can i just JB Weld them? I am not about to replace the crankshaft.
 
so, i guess the pic the didnt upload.
but what is my best option? it is the nubbs under the 19mm bolt on the right side of teh engine that turns the crank.
 
Are you talking about the lobe that the points ride on? :confused:
What "nubbs?"

Eric
 
How are they "broken?" Those are the pick-up points for your electronic ignition.

Eric
 
i took the bolt off already and there are two sheared off spots where there used to be the nubs. they point in the direction of the crankshaft.
 
I don't have factory elec. ignition so I don't know what is missing. Perhaps some kind of insulator? Someone will chime in and explain it to both of us, I hope. I would think that whatever it is, it is replaceable. ;)

Eric
 
He is referring to the END of the mechanical advancer where it has 2 outward "pins" that locate the outer nut on the end of the crank that holds the mechanical advancer on. All you need to do is get another mechanical advancer! You crank is fine! I have attached a picture. Ray.
 
Thanks for posting the pic Ray! I knew that it could not be THAT bad... :)

Eric
 
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