how to install piston rings on 4 stroke motorcycle

Modern oil control rings typically utilize a three-piece design and consist of two side rails and an expander ring. Changed the breakin oil at 100 and I'll run 400 miles of breakin oil  before I go back to synthetic. ProX pistons are available in multiple sizes to accomodate for cylinder wear, so be sure your bore measurements correlate with the size of piston you're installing. \r\rIf I can ever be of service to you, here is a video explains how to connect with me. Here's how to do it right. For 10 seconds winding the starter it’ll have compression, the next 10 seconds it wont have compression while winding the starter. Now you can loosen the head bolts in incrementally in a crossing pattern. Release the tension of the ring installer tool. Click here to see what's available for your machine. Lightly oil the ring and then carefully work it over the piston into its appropriate groove. Buell XB9R Big Bore Installation. On a four stroke engine, you can have a one-piece ring or a three-piece ring. With years of performance piston experience, JE knows ring operation is just as important as piston quality. I hate to take it to a shop, i do everything myself. By If both top and 2 nd rings have a dot and your set has a coating, the OD will be metallic in color where as the 2 … Install the compression ring(s) in a similar fashion, lightly applying oil and carefully working the ring around the crown of the piston. If you have an account, sign in now to post with your account. Check out our guide here. if i keep winding on the starter it gains and looses compression over a certain amount of time. Measure the piston on the skirt, 90 degrees from the wrist pin bore, at the point on the skirt that is 1/4 of height of the piston from the bottom. M-Series Piston Installation. Kevin Bailey. On the first ride, she lasted a couple of laps and ran beautifully, until it just locked up. FRM Bores Installation. 11/5/2017 0 Comments How to do a Top End Rebuild on a 2 stroke motor. Use the normal motor oil you use in your 4-stroke. Also, custom service is available. While not always required, removing the sub-frame, shock, and air boot make accessibility to the engine a lot easier in most cases. Next, lay your new base gasket on the cases, lining it up properly. Skirt diameter is smaller than the recommended bore size (see sizing on box). Brand Name: ANERDA, AED ,TOR or OEM Type: Motorcycle Engine 4 Stroke Spare Parts Min Order: 100 Sets Next, remove the cam cover, loosening the bolts incrementally until they are all loose. Anyways, my question is whether or not you think this original cylinder can be saved somehow without having to order another brand new one - part of the wrist pin is still lodged in it. Piston installation can be done via more than one method, but in our case, we installed the piston in the cylinder before attaching it to the connecting rod. In addition to understanding the steps you'll be performing, laying out all the components needed helps stay organized and prepared. We plan to tear apart the bottom end and see if any pieces of the wrist pin bearing are floating loose around there and will hopefully find an undamaged crank & will get any pieces out to keep this from happening again. Finally, you can remove one wire lock from the stock piston using a pick or small screwdriver. Work the opened ring down from the top of the piston to the oil groove. There will be markings on the crown of ProX pistons to indiciate which side is the exhaust side. Before cleaning, confirm the ring ends are free of burrs. While installing the piston rings onto the piston is a critical step in the build process, it can be performed by anyone when the proper steps are taken. At JE Pistons, the ring end gaps are preset at the factory to fall within spec when installed in healthy cylinders used for normal applications. This project is a work in progress for my XR650L. For proper installation, it is imperative that the expander’s ends butt and do not overlap. I’m sending cylinder to get done and installing new piston just want to prevent and figure out why it’s happening. If you're unsure about performing any cylinder prep work yourself, talk to your local dealer about cylinder shops, where any prep work required can be performed. Install each ring carefully and slowly, moving from the bottom to the top. I ended up taking the top end apart and found that the exhaust side of cylinder and piston are scored I can catch my nail on scratch’s. ANERDA is one of the most professional 4 stroke motorcycle piston ring manufacturers and suppliers since 1997.   You cannot paste images directly. Make sure the side rails sit correctly against the stepped edge of the expander ring and that their end gaps are positioned properly. Carefully work the ring past the compression ring groove into the oil ring groove. Clean the piston head and the slots of the rings if you are replacing an old ring. I posted my failure so that others won't make the same mistake or a similar one. The end gap of the first compression ring should always be less than that of the second compression ring. Measure the piston on the skirt, 90 degrees from the wrist pin bore, at the point on the skirt that is 1/4 of height of the piston from the bottom. The other feature of the expander ring worth paying attention to is its ends. Click here. Briggs & Stratton Installation. 4. To prepare to disassemble your head and cylinder, you'll need to remove the seat, gas tank, exhaust system, and carburetor (or throttle body). If using the three-piece ring, stagger the gaps around the piston one-half to one-third rotation to help maintain compression. Visit this link for instructions how to enable JavaScript in your web browser, Mark piston where the end gaps should align. Before diving into installation details, a quick recap of the process will be helpful to understand what’s to come. The top end in a four-stroke can be split up into two major sections: the head, and the cylinder and piston. Contact Taiwan Motorcycle Piston supplier-IRITA INTERNATIONAL CO., LTD. for motorcycle, engine, piston, ring, piston ring, scooter, snowmobile, oem, aftermarket, taiwan on Taiwantrade. Recently you saw our introduction video telling you about our used 2006 YZ450F that we're rebuilding and documenting step-by-step. When measuring ring end gap, install the top ring and second ring (seperately, and if applicable) approximately 1/4" into the bore. Need clarification on all the markings used on JE rings and pistons? Note the thickness of the gauge and compare it to the end gap specifications provided. However, be gentle and careful not to put deep grooves or scratches in the surfaces. × Instead, the oil rings weren't functioning properly so oil was dripping out my exhaust. Note: Make sure you take any rags out of the cases before reassembling! Install New Piston Rings. It is always a good idea to fill the opening of the cases with a lint free rag to prevent debris or loose parts from falling in. Use the depth rod end of a caliper to ensure the ring is square to the bore. To do so, insert a feeler gauge between the ring and groove. PLEASE READ CAREFULLY BEFORE INSTALLATION. September 24, 2020. Sorry if its a no-brainer but I hate to wait for more rings to come in the mail if there's no reason to. Install the spiral brace spring into the ring groove , and then put the ring body into , The spring joint is located opposite the beginning of the ring body . The side rails are also non-directional. All custom made products are with high quality and competitive price. Jeff Slavens demonstrates how to install piston rings. Originally the shop I bought the bike at replaced the oil during the 100 mile checkup with synthetic. Refer to your manual for acceptable piston-to-wall clearance range. Would you have it bored? The machine’s factory service manual should also be on hand throughout the build so that things like torque specs, service limits, and procedures can be referenced. Use your finger to put a layer of motor oil on the cylinder wall. How to install piston rings 4 stroke. Keeping the GAP on the TOP ring, 180 Degrees away from the Intake valve helps keep unburnt fuel to 'flow' into the gap increasing 'Wash down,' that will wear the rings, piston and cylinder VERY quickly. For large or difficult pieces of material, it is common to use a razor blade for removal. With the piston secured to the connecting rod via the wrist pin, install your remaining wire lock, and make sure it is properly seated. I've learned that using synthetic that early prevents the rings from fully seating in. Complete Guide to Installing Motorcycle Piston Rings. Probably best to wait at least 500 miles before you switch to synthetic. Carefully insert various thickness feeler gauges between the ring ends until the gauge just begins to drag between the ring ends. Use a feeler gauge for this and find the size that has slight drag. Use a feeler gauge to be sure ring end gap is within the dimensions specified in your piston kit instructions. Once the side rails have been installed, double-check the end gap positions of all three rings that comprise the oil control ring assembly. Any burrs present can carefully be dressed by gently breaking the edge with a small file. At JE Pistons, comprehensive instructions are included with most new piston kits. JE now has pistons available for many late model applications. Final cleaning commonly consists of using carb cleaner, or a similar chemical cleaner, and a rag to achieve completely clean and flat surfaces. Step 4 - Replace the Pistons and Engine Top Currently breakin's at over 400 miles. Thank you all in advanced. We're well-known as one of the leading 4 stroke piston ring for motorcycle engine part manufacturers and suppliers for our quality products and competitive price. Upload or insert images from URL. If you are using your fingers, be careful not to bend or expand the piston rings too much, otherwise they will break. Remove small amounts of material and check the end gap periodically so that you don’t remove too much material. Before installing the rings onto the piston, it is imperative that the ring end gaps are checked and verified against the specs provided with the installation instructions or factory service manual, whichever is applicable. Tech. © ProX Racing Parts. This task is perceived by many to be simple. With the cam caps removed, loosen and remove the cam chain tensioner next. We are expecting become your long team partner in China. This includes the base for the cylinder on the cases, top and bottom surfaces of the cylinder itself, and the bottom surface of the head that seals to the cylinder. Start by installing the expander ring after lightly coating with oil. We supply high quality 4 stroke motorbike piston ring. Make sure your rings are clean and free of any debris or burrs. You don't want your new piston and rings breaking in under dry conditions. Once those major components are removed, you'll need to remove any other components attached to the head or cylinder, such as clutch cable guides, spark plug boots, and electrical connections. You can do this by slowly rotating the crankshaft via the kickstarter. To do so, use a small file and file one end of the ring. The majority of JE's motorcycle rings are pre-gapped, but it's always good practice to check ring end gap for all compression rings prior to installing on the piston. Adjust the expander ring as necessary, so the ring ends are correctly positioned. Clear editor. Piston rings are fickle and require patience to position them correctly. Display as a link instead, × Three-piece oil rings can be challenging to install if the ring design and methodology are not understood. × Be sure they are resting evenly and the end gaps are lined up with the appropriate markings. Kit includes a Vertex piston, rings, wrist, pin, circlips and a top-end gasket kit. Then I slide the cyl down to the rod (and bearing on a 2/stroke… In the simple, two-stroke days of riding and racing, rebuilding a top end was just a matter of slapping a new piston and rings in, maybe with a little cylinder clean-up thrown in for good measure. Gapping and correctly installing piston rings is one of the most important parts of engine assembly. BTW, I chose the hard breakin method and not the manufactures slow breakin. Three-Ring Piston Designs. Head back for part 2 of the the top end rebuild, where we'll show you some great tips on assembling a four-stroke head with new valves and valve springs, re-installing camshaft(s) and timing chain, and checking and adjusting valve clearance. January 31, 2011 Engine Videos, Video. Note the groove clearance and compare it to the specification provided in the installation instructions or factory service manual. Remove the head and place it aside, handling it carefully. In search of a quality, performance forged piston for your bike? This will give you the slack to remove the timing chain completely. Install Piston Rings 4 Stroke. Doing so will help ensure no orientation mistakes are made upon ring installation. A step by step instructionpictorial on how to change out a pistonrings etc on a 2 stroke motor. Copyright© ThumperTalk, Inc. - All rights reserved.ThumperTalk® is a registered trademark. This process can be repeated for any additional compression rings used. So I messed up and got 66mm rings instead of 65.5 which I believe is the correct size rings for stock bore on a 1990 xr 200. The best method is to partly install the piston into the barrel on the workbench, where you can easily pinch the rings together and ensure they’re lined up correctly. At this point, ring installation onto the piston is complete, and subsequent steps can be taken to complete the engine build. Bike runs good on low idle no problem as soon as I go W.O.T or higher revs bike will start sounding as if it’s a 4stroke and it shuts off slowly. Re-sleeved? Here are proven methods for how to install piston rings easily and BONUS: Oil ring close up and theory.\r\rThank you for watching. Fear no more. Install the rings in the proper order and location on your pistons. When you have your cylinder prepped and ready, now is a good time to double check your piston-to-wall clearance and ring end gap. Piston replacement intervals are typically outlined in your machine’s factory service manual. It made the rings stick. In this article, we’ll walk step-by-step through the ring installation process so that the next time you’re rebuilding your engine, you know exactly what to do and what to watch out for. If more than one compression ring is used, confirm any design differences between the two by referencing the installation instructions. Also remember, on a 2/stroke, to position the Ring ends to the peg in each ring groove. Follow along with our complete guide to installing rings on your motorcycle piston(s). As you remove the cylinder, the piston is going to stay on the connecting rod, so it helps to hold the connecting rod steady as you wiggle the cylinder off the piston. I showed the overlapped expander to a buddy that used to build 2 stroke motors. The pistons are available in A, B, and C sizes, to accomodate for the size of your cylinder as it wears. Not sure which piston ring set you need to order? Next, use feeler gauges to measure the ring’s end gap. Improper installation of the piston rings can result in limited engine life, reduced power, and high oil consumption. Pictures for reference. Be careful not to twist or overlap them. Install the dot toward the top of the piston. RM85 CYLINDER DONE FOR - CAN THIS BE SAVED? Detailed info about 4 Stroke Piston Ring for motorcycle engine part use.   Pasted as rich text. This time the brand new piston and cylinder look worse ( the piston was gouged on both sides and one side of the piston was actually crushed in - no pics of that, I was too upset), although no pieces of anything came out with it when we took it apart - just saw all the gouges in the brand new cylinder and piston .   Your link has been automatically embedded. Its very weird ive never seen anything like it. Ring Gaps 15 pins in between and to TDC. Install the compression ring(s) in a similar fashion, lightly applying oil and carefully working the ring around the crown of the piston. You can install your new piston rings with your fingers or a ring expander tool. A great way to take full advantage of the 21st Century engineering that goes into piston rings is optimize the break-in / ring seating procedure. Refer to the instructions that come with ProX piston kits to be sure you are installing the rings in the correct fashion and location. Next, use your preferred parts cleaner to wipe down the rings and piston. The piston ring provides a seal on the top of the piston and aids in heat management. For piston-to-wall, measure the size of your ProX piston using a micrometer only. We devoted ourselves to motorcycle piston rings many years,covering most of Europe, America, Africa and Asia market. Be careful not to twist or bend the ring out of shape as it could affect its ability to seal properly. My bike has been giving me issues and I can’t figure it out. If ring end gap does need to be adjusted, evenly file one end of the ring only in small increments and continue to check until it's at the desired spec. The expander ring is the waffle shaped ring and features a stepped edge on the top and bottom of the ring. Using dirt bikes as an example, many manufacturers outline a piston and ring replacement schedule of every six races or 15-30 hours for a four-stroke, depending on the machine. For starters, never attempt ring installation without the appropriate documentation available for reference. There will be markings on the crown of ProX pistons to indiciate which side is the exhaust side. If there is minimal glazing on the cylinder, no grooves worn in, and it's within spec, you should be ready to reinstall after a good honing. Do not scrape the carbon from the grooves. FC 7.5.1-69 -----FC 7.5.1-30. Shown below is an outline of the major steps you’ll go through. The clearance can be identified by finding the feeler gauge that drags ever so slightly between the ring and groove. Typically, dots or letters will be marked near the ring end, which denotes the top of the ring. Spider Tech If the piston utilizes two compression rings, the second compression ring should be installed first. Copyright© ThumperTalk, Inc. - All rights reserved. Find the performance you've been looking for. Compare this spec to what's outlined in your instructions or owner's manual. Restore formatting, × Bike has 70hours and I’m pretty sure top end was never done. Adjust the ring’s end gap position so that it aligns with the mark you made for it on the piston crown. However, there are vital aspects of ring installation that should not be overlooked. It includes the rings, wrist pin, circlips, and installation instructions. Will Suzuki Succeed at Reinventing Itself? To install the expander ring, lightly coat it with engine oil. The install didn't have stuck rings anymore so I thought I was good to go. Chemically clean the piston head with a dip-style carburetor cleaner. When using a two piece oil, install the hump style spring in the groove then follow the above instructions. My 350 with almost 13,000 miles is  running great. Refer to the installation instructions to determine the proper orientation of the ring before installation. Be careful not to twist or bend the ring out of shape as it could affect its ability to seal properly. From looking at pictures I assume this should also work for the XR600 and X650R, with a few modifications. Welcome to wholesale bulk 4 stroke motorcycle piston ring for sale here from our factory. Ring End Gap/Installation. ProX takes you through the major parts of rebuilding a 4-stroke top end complete with step-by-step guides for each task along the way! When fitted, the opening of each ring should be staggered , the angle of each stagger is 90° , 120° , 180° etc , and do not put the opening in the piston ring , should be closed after the ring to gently push into the cylinder liner. To check the ring end gap, simply install the appropriate ring into the cylinder bore and position it near the top of the bore. No warning signs, no hard shifts, no lag, no warning at all - just stopped. The process simply requires the correct measurements are taken, cleanliness is ensured, and installation techniques are used. Some features of this site require JavaScript. All piston rings should be cleaned before being assembled onto the piston. Please subscribe and share my work! Please feel free to wholesale 4 stroke piston ring for motorcycle engine part for sale here from our factory. While you’re there, install a circlip on one side of the piston to make life easier when you’re putting the … Either way, be sure your piston is facing the correct direction, meaning the exhaust valve reliefs line up with the exhaust side of the head. As we’ll see, the process is somewhat specific and less than rewarding if you screw it up! 4-stroke pistons apply to a variety of different engine types in powersports, and many of them use 3-ring designs. When measuring ring end gap, install the top ring and second ring (seperately, and if applicable) approximately 1/4" into the bore. Also, don't cut your finger open, or off. Distributed by Tubemogul. You're now at the point in reassembly where you will install your rebuilt head (details in part 2 of this top end rebuild soon to come) with the proper head gasket, and re-install all the items previously removed. Internal edge features such as chamfers may also be used to identify the ring and its correct orientation. Find one here! Find the performance you've been looking for. Oil and install the oil expander rails below and above the expander. More maintenance and rebuild tips to come! We ordered a new wiseco piston & rings and replaced them - the bike fired up and ran for about 5 minutes before the wrist pin shattered and lodged part of the bearing in the cylinder wall (simultaneously destroying the new piston & ruining the cylinder - see pics). Connecting Rod Installation. It's important to read and understand any assembly and installation instructions that come with your pistons. Be sure to maintain parallelism to the other ring end as you remove material. Video Tutorial: Jetting 101 for beginners, Some features of this site require JavaScript. It will pop and shoot flames when it has compression but sometimes it’ll just spin freely with no compression sounds. Doesn’t do it 100% of time but half the time yes. The ends of the expander ring should be touching, but not overlapping. This goes way beyond just choosing the right break-in oil, although that’s an excellent start. [How to] LED Headlight for XR6XX X for 40-50$, Rekluse Auto Clutch: Everything You Need to Know, How to Rebuild the Top End in your Two-Stroke. Be very careful no to drop anything into the cases during this step, and throughout the entire process. After this, install one wire lock into your piston, being sure it is properly seated. Topics: We break down the newest advancements in four-stroke piston rings, and how these technologies can benefit engine builders and motorcycle riders alike. We're well-known as one of the leading piston ring for motorcycle 4 stroke manufacturers and suppliers for our quality products and competitive price. Use a marker to mark the edge of the piston crown with the intended ring end positions for the oil control and compression rings. How to Install 2 Stroke Piston Rings. Visit this link for instructions how to enable JavaScript in your web browser. Lightly lube the side rails then install them on the piston. Chamfers on the inside edge of the ring or different markings at the ring ends are common identifiers used to denote ring differences. We replaced the worn stock piston with an OEM quality forged ProX piston kit. Can I just gap to spec and send it or do I need to buy some 65.5mm rings?? Refer to your manual for acceptable piston-to-wall clearance range. 2-stroke applications include a wrist pin bearing. Also, make sure your rings remain in the proper location as you slide the piston into the cylinder. First time here and needing help to figure this out thanks in advance. Assuming no issues are found with the measurements or cylinder bore and the end gap measured is too tight, the rings can be carefully filed. Parts that are altered, scratched, or damaged are non-returnable. You can now slide the cylinder all the way down to meet the cases. Before buying a car you have to … Next, put a layer of oil on the outside of your new piston (on the outside of the rings, on the ring belt, and on the skirts). Place the ring squarely into the piston groove, taking care to keep it flat. In this part 1 video, we'll go over tips on replacing a four-stroke piston. Review the instructions provided with your piston kit, or the guidelines provided in your owners manual if no alternate instructions are provided, and note the specified positions of the ring end gaps. The instructions I had really were geared toward someone that had experience with this type of build. Please feel free to wholesale piston ring for motorcycle 4 stroke for sale here from our factory. Be sure you are following all proper torque specs specified in your manual. Exact fit A, B, or C pistons match the cylinder bore perfectly to maximize power and performance. Repeat this process for any remaining compression rings. These instructions are for representational purposes only and not valid for all JE pistons. Once the compression rings have been installed, the ring-to-groove clearance should be checked. ProX rings are pre-gapped, but it is always good practice to double check. With everyting removed, you'll need to clean any old gasket material and other residue off your sealing surfaces. Click here for our tips on installing wire locks. I bought a drz400 in pieces but the motor was assembled just put the wiring harness and all those goodies back on. All Rights Reserved.
how to install piston rings on 4 stroke motorcycle 2021