piston ring issue/impossible screw tips?

[GroovyAardvark]

Hey guys,

Finally re-building the 100 cc kawasaki G4 motor and I have run into 2 problems.

1.) Got new piston rings and put them on easy. Problem now is they are not flush with the piston. They are the correct size for the right piston etc, the gap is just too big and I cannot put my head back on until the rings are flush. Is there any trick to this?

2.) There are 7 screws on this thing that will not budge. I have tried, icing them, WD40, and just good old fashion muscle but the result? Some very soft and semi stripped screws. I am basically down to using an impact driver on them, but I was really hoping to avoid that as I don't want to track down 7 replacement screws. I would love to hear other peoples tricks for dealing with stuck 35 year old screws.

Many thanks,

 

[crazypj]

I think they are keystone rings, tapered on top edge.
You did put them on the right way up and line them up with stop pins on piston?

PJ

 

[Rocan]

impact driver is the only way i can get them out without stripping them. manual ones work a bit better/strip less.

not replacing them is dumb. replace them all with stainless allen head bolts. if you ever have to remove covers again, youll be thankful.

 

[GroovyAardvark]

Well I ended up impacting the screws out. No major dramas there.

Still cannot get the piston into the head.
Yes the rings are in the correct position and the right way up.
Tried a piston tool on it, but it was too large. Having trouble finding a tool sleeve that would fit a 100cc .50 piston.

Any suggestions?

Many thanks as always.

 

[Swagger]

Check at a small engine repair shop, one that services mowers and chainsaws and snowblowers and such. Likely they'll have a ring compresser to sell or can tell you where to get one.

On a completely different note.....whatever happened with your wiring issues on Helena's (sp?) bike?
Ever get that sorted?

 

[GroovyAardvark]

Thanks Swags, I'll swing past a small engine repair place and see if the have a compressor that fits. Never even thought of that!

Ah, the old CB360. I actually sold it, and bought a Buell blast for the misses to learn on. Took her out for her first real spin today. She is learning quickly. It's a great bike for her. I would have loved to keep the Honda but we are planning to move to California in the near future and transporting 3 - 4 bikes is too much. I am trying to sell the xs360 at the moment as well. Just keep the Buell as a learner and daily rider for now, one project bike at a time, ie. the Kawasaki. Probably only take the Kawasaki to CA with us, and sell the Buell.