How to Remove Pistons

Energy One
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Dakotabos

Dakotabos

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Tear Down
Remove Exhaust & Ignition Coil Assy

Remove Carb




Remove 6 Bolts on Valve Cover


Remove 5 Bolts on Vavle


4 bolts off Valve Housing


Remove Push Rods (Mark FRONT AND REAR)


Disconnect Compression Release under Seat


Cut Wire and Remove Ground wires


Use safety wire to pull through frame (LATER)


Lay to the side


Remover 4 1/2 inch 12 point head bolts


Watch out for Guide pins while removing Heads


Using rubber Mallet remove Cylinder (DO NOT FORCE) Hit at 90 Degree


SUPRISE Found Broken Top Piston Ring (On Rear Cylinder)


Forward Piston Found 1" Piece GONE!!!!!!




Both second Piston rings Frozen


No Damage to Cylinder Heads or Valves


Rotate engine (Put bike in gear turn rear tire)


Put rags in all Holes


Remove sir clips on Both Sides


Pull Piston Pins


Pistons are Marked on Bottom




Keep Shit Seperated (Front rear and OTHER)


NAKED DOG


Bad PISTON Ring


BAD FORWARD PISTON
 
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lee

lee

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

hoat

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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
 
V

Vegas

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

05chop

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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.
 
Dakotabos

Dakotabos

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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.
 
kickstart

kickstart

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hoat said:
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
Click to expand...
My thoughts exactly, I might even have to split the cases. I couldn't sleep right if I didn't!
 
05chop

05chop

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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.
 
Dakotabos

Dakotabos

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No it wasnt

Back ring was in 20 pieces this is it



Laying on Bench

 
T

TheDeadOne

Banned
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!
 
05chop

05chop

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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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