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post #1 of 5 (permalink) Old 03-06-2015, 07:04 PM Thread Starter
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Rebuild 2008 650 ROUND 2!

Lets start off by saying unless this entire motor is sitting on a bench it's a huge pain in the A$$ to do this job!!!!
There is no way in gods name that you can slide the cylinder over those royal pain rings! So what I did was I put the piston set in the cylinder FIRST! I did this 2 times because I feel the piston is tight, I mean like you really have to push hard to get it to move in the cylinder. I'd think it would slide with ease?? Let me tell you, it took me around 5-6 hours just to get the piston and rings into the cylinder! Yes FIVE TO SIX HOURS! Those bottom rings (3 piece) almost sent me to the saloon! IF THEY OVERLAP YOU START OVER. AND THEY OVERLAP NEARLY EVERY TIME I TRIED TO INSTALL THEM!
SO WHAT'S THE TRICK? I now wonder if I'm overlapped again?? Should it be that tight? And yes it is the correct piston and rings, not oversize.
HELP PLEASE! I'm stuck right here until I know if it's to tight to put back together. Maybe I should slide the old piston set in and see how that slides! Then start all over again?
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post #2 of 5 (permalink) Old 03-06-2015, 07:52 PM Thread Starter
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Originally Posted by catman2 View Post
Lets start off by saying unless this entire motor is sitting on a bench it's a huge pain in the A$$ to do this job!!!!
There is no way in gods name that you can slide the cylinder over those royal pain rings! So what I did was I put the piston set in the cylinder FIRST! I did this 2 times because I feel the piston is tight, I mean like you really have to push hard to get it to move in the cylinder. I'd think it would slide with ease?? Let me tell you, it took me around 5-6 hours just to get the piston and rings into the cylinder! Yes FIVE TO SIX HOURS! Those bottom rings (3 piece) almost sent me to the saloon! IF THEY OVERLAP YOU START OVER. AND THEY OVERLAP NEARLY EVERY TIME I TRIED TO INSTALL THEM!
SO WHAT'S THE TRICK? I now wonder if I'm overlapped again?? Should it be that tight? And yes it is the correct piston and rings, not oversize.
HELP PLEASE! I'm stuck right here until I know if it's to tight to put back together. Maybe I should slide the old piston set in and see how that slides! Then start all over again?
Slid the old piston in without the bottom rings, slide much easier. Pulled the new piston and ring set out, did the same as the old and it slid easier. It's those phony rings on the bottom. UGH
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post #3 of 5 (permalink) Old 03-07-2015, 03:55 AM
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I have not had any problems putting the cylinder over the piston and rings, I set the rings in the cylinder and gapped them per the specs., I have a piston ring compressor that I use to compress the rings on the piston, oil everything good and start the cylinder over the assembly. It does not take much force. If you have to force the cylinder, stop and recheck your work, something is wrong.

2009 700EFI XTX, , AC Winch, 2010 Dust Shield EPI Sport Utility Clutch Kit , Street Legal, Cage chopped 2 ", Aluminum Diamond Plate Trim, Relocated Factory Bladders with covers, 5 Pt. Harness installed, Bed Tiedown System, Scat Pro-Car Seats, Secondary Battery installed, Oil Pressure, Oil/CVT Temperature, Volt Meter & Water Temp Gauges installed with Dash Plate, Bighorns, ITP Black 212 Wheels. Tonneau cover. 750 Big Bore Kit, Web Cam, and Rocker Arms.

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post #4 of 5 (permalink) Old 03-07-2015, 12:17 PM Thread Starter
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I have not had any problems putting the cylinder over the piston and rings, I set the rings in the cylinder and gapped them per the specs., I have a piston ring compressor that I use to compress the rings on the piston, oil everything good and start the cylinder over the assembly. It does not take much force. If you have to force the cylinder, stop and recheck your work, something is wrong.
Went and picked up a ring compressor to see if that makes a difference.......
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post #5 of 5 (permalink) Old 03-08-2015, 05:41 AM
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Should help greatly! Doing by hand is almost impossible! Mine has a handle that ratchets the amount of compression, and then when done releases the band completely so you can slip it off.

2009 700EFI XTX, , AC Winch, 2010 Dust Shield EPI Sport Utility Clutch Kit , Street Legal, Cage chopped 2 ", Aluminum Diamond Plate Trim, Relocated Factory Bladders with covers, 5 Pt. Harness installed, Bed Tiedown System, Scat Pro-Car Seats, Secondary Battery installed, Oil Pressure, Oil/CVT Temperature, Volt Meter & Water Temp Gauges installed with Dash Plate, Bighorns, ITP Black 212 Wheels. Tonneau cover. 750 Big Bore Kit, Web Cam, and Rocker Arms.

Either - Dick or RD
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