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Author Topic: The journey of a piston circlip. ENGINE CARNAGE!  (Read 390 times)

Offline Archer97

  • Posts: 17
  • Snow, the other white drug.
The journey of a piston circlip. ENGINE CARNAGE!
« on: May 17, 2017, 16:30:44 »
Not a cafe but I figured y'all would appreciate this. Took the GFs 1972 Kawasaki G5 (100cc rotary valve 2 stroker) round the block about a week ago. I made it about 2 miles and it just cuts out like I flipped a switch. Okaayyy..... call my dad and we get the bike home and I didn't get to look at it till today.



Spark? check. Compression? A tad low but should run. Fuel? Nada, plugs dry as a bone. So I pull the carb cause I figured something clogged it really good however unlikely that may be. Took a glance at the fiber rotary valve and spun the motor over, wtf? The valve is siezed! So the motor would spin but the valve was still covering the intake. Found my problem right!?



I pulled the rotary valve cover off and it looks like a goddamn paper clip jammed my  valve and shattered the 45 year old fiber disk. It took me a second to realize what I was holding was a piston circlip.





 Well I pulled the head and just had a couple minor scuffs on the cyl wall. Could catch a nail on them so I breathed a sigh of relief.

Then I pulled the cylinder to replace the wayward clip and I sucked that sigh right back in.







 The clip smashed the intake port, gouging the lower piston and cylinder before catching on the fiber rotary valve where it siezed the valve and broke it loose from the retaining ring. A $0.50 circlip took out the two of the hardest parts to find on these bikes. Yay.

Anyone got a good source for a new cylinder and fiber rotary valve?

Sent from my SM-G930P using DO THE TON mobile app

I bought a bike so I still have something to fix in the summer while the sled is waiting to break in the winter.

Offline julian.allard66

  • Posts: 278
Re: The journey of a piston circlip. ENGINE CARNAGE!
« Reply #1 on: May 17, 2017, 18:03:41 »
Had one come out on a 350LC in 1987, did far more damage than that.

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Offline cxman

  • DTT SUPPORTER
  • *
  • Posts: 2317
Re: The journey of a piston circlip. ENGINE CARNAGE!
« Reply #2 on: May 17, 2017, 18:29:09 »
lots of rotary valves on ebay even a nos one for 29$

there are some cylinders and pistons to
1978 CX650 Super Deluxe
1979 XS1100 Special
1980 XS650
1980 cx500  The Beast
1983 GL650 i
1983 cx650 Custom
1973 CB450
1973 cb750
1980 cb750
1981 cb650
1982 cb900 c
1977  gl1000
1976 gl1000 LTD
 1983 GL1100 Nekid
and a bunch of others

Offline TheCoffeeGuy

  • Posts: 608
  • Books, Books, Books, knowledge is within
    • The Coffee Guy's Blog
Re: The journey of a piston circlip. ENGINE CARNAGE!
« Reply #3 on: May 18, 2017, 08:39:55 »
I did that before.   Make sure that the gap in the pin clip is either at the very bottom or the very top.   Otherwise the up and down of the piston can allow for the momentum of the clip itself to compress enough to come loose if the gap in the clip is at the side.
www.thecoffeeguy.ca Not your ordinary Blog site.

1968 Harley Aermacchi ML 125 Rapido, restored
1972 Honda Cl 450 engine rebuild, a day rider soon, now sold
1980 Suzuki GS850GL Street Brat  My other day bike
2000 Harley 1200 Sport S My day bike
1982 Honda CB650 Chopper light

Offline raptormeat

  • Posts: 389
Re: The journey of a piston circlip. ENGINE CARNAGE!
« Reply #4 on: Aug 02, 2017, 19:34:08 »
I did that before.   Make sure that the gap in the pin clip is either at the very bottom or the very top.   Otherwise the up and down of the piston can allow for the momentum of the clip itself to compress enough to come loose if the gap in the clip is at the side.

Now THAT...is some knowledge of experience. Great advice, glad I forget how I put mine in. Ignorance is bliss.
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