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How to Remove Pistons

Discussion in 'How-To' started by Dakotabos, May 12, 2009.

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  1. Dakotabos

    Dakotabos Admin
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    Tear Down
    Remove Exhaust & Ignition Coil Assy

    Remove Carb
    [​IMG]
    [​IMG]


    Remove 6 Bolts on Valve Cover
    [​IMG]

    Remove 5 Bolts on Vavle
    [​IMG]

    4 bolts off Valve Housing
    [​IMG]

    Remove Push Rods (Mark FRONT AND REAR)
    [​IMG]

    Disconnect Compression Release under Seat
    [​IMG]

    Cut Wire and Remove Ground wires
    [​IMG]

    Use safety wire to pull through frame (LATER)


    Lay to the side
    [​IMG]

    Remover 4 1/2 inch 12 point head bolts
    [​IMG]

    Watch out for Guide pins while removing Heads
    [​IMG]

    Using rubber Mallet remove Cylinder (DO NOT FORCE) Hit at 90 Degree
    [​IMG]

    SUPRISE Found Broken Top Piston Ring (On Rear Cylinder)
    [​IMG]

    Forward Piston Found 1" Piece GONE!!!!!!
    [​IMG]
    [​IMG]
    [​IMG]

    Both second Piston rings Frozen
    [​IMG]

    No Damage to Cylinder Heads or Valves
    [​IMG]

    Rotate engine (Put bike in gear turn rear tire)


    Put rags in all Holes
    [​IMG]

    Remove sir clips on Both Sides


    Pull Piston Pins


    Pistons are Marked on Bottom
    [​IMG]
    [​IMG]
    [​IMG]

    Keep Shit Seperated (Front rear and OTHER)
    [​IMG]

    NAKED DOG
    [​IMG]

    Bad PISTON Ring
    [​IMG]

    BAD FORWARD PISTON
    [​IMG]
     
    #1 Dakotabos, May 12, 2009
    Last edited: May 12, 2009
  2. RCAdd1ct

    RCAdd1ct JAFO
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  3. Dakotabos

    Dakotabos Admin
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    DAMN SMALL PICTURE
    F*&K It I will fix it in AM
     
  4. RCAdd1ct

    RCAdd1ct JAFO
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    It's a good write up. Sorry you have to do it, though.
     
  5. BorgerBigDog

    BorgerBigDog BORN TEXAN

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    Pretty cool to take the time posting :cheers:
     
  6. chacha

    chacha Chaff Your EHC!!
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    Good Stuff! Amazing what ya find when ya open these up!
     
  7. lee

    lee Well-Known Member

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    I repeat what I said before - I feel for you. Any idea what caused this to happen?
     
  8. hoat

    hoat Well-Known Member

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    Great write up. Do you think that you got stuff in the bottome end?. I think there is a plug in the bottom of the cases. I wonder if its worth douching that sucker out?

    Just a thought maybe someone else can weight in
     
  9. Vegas

    Vegas Well-Known Member

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    What a mess huh...looks like it may have been running lean. The piston in the hole is pretty clean.
     
  10. 05chop

    05chop Well-Known Member

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    Can you turn the piston upside down and take a picture of the bottom side for us . Is the bottom side all discolored? Also can you see any cracks on the piston? From this picture it sure looks like de-bonding or faultily piston material too soon to tell though. [​IMG]
     
  11. Dakotabos

    Dakotabos Admin
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    The problem is I ride at 4000 then up at 10,000 above sea level then at sea level out in San Diego. Wish I could change it on the fly

    I think tonight I will dig deeper means I am waiting on Parts. I have to order them today just want to make sure I get the right pistons on order today. They are comming from Wisconson and I will order them 2 day air so should be here Friday.
     
  12. Dakotabos

    Dakotabos Admin
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    [​IMG]

    The bottom side is CLEAN Wierd Huh

    [​IMG]

    Sides Clean too
     
  13. kickstart

    kickstart Well-Known Member

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    My thoughts exactly, I might even have to split the cases. I couldn't sleep right if I didn't!
     
  14. Dakotabos

    Dakotabos Admin
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    [​IMG]

    WHY OH WHY
     
  15. 05chop

    05chop Well-Known Member

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    See if you can make a complete circle out of the broken ring! Im not sure on this motor but im assuming it has piston oilers correct? That ring broke after the piston broke loose my guess. You can barely see small cracks on the piston crown I was looking for a picture of the bottom side of the exposing the broken piece for excessive heat.
     
  16. Vegas

    Vegas Well-Known Member

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    Were the rings broken in exactly the same spot?
     
  17. Dakotabos

    Dakotabos Admin
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    No it wasnt

    Back ring was in 20 pieces this is it

    [​IMG]

    Laying on Bench

    [​IMG]
     
  18. TheDeadOne

    TheDeadOne Banned

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    D,
    What the hell is that somewhat white looking sh*t above the oil ring,in the groove? (edit) now I see, it's on the bottom side of the scraper ring. But what is it? I've built a lot of race motors, and never seen anything like that white sh*t. I've seen the way the rings are broken before. It's from ring expansion!
     
  19. Dakotabos

    Dakotabos Admin
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    Dead1 bad picture not white
     
  20. 05chop

    05chop Well-Known Member

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    Are you going to check the valve seats while you got it down? Small material off of the piston can mark the exhaust seats looks like you have good shop tools.
     
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