Piston Pin Removal

I am in the process of disassembling my KZ1100 motor, and I cannot remove the piston pins. My manual says that the pin should be able to be pushed out by finger. I couldn't move them at all by finger. Then the manual says to heat the piston with a warm rag, and then push the pin out. That helped move the pin on #1 piston to be in line with the connecting rod. The manual says if the pin still will not come out, use a C-clamp and a rod to push the pin out. I do not want to damage the connecting rods, so I was wondering if anyone has any ideas or alternatives. What is the risk of damaging the piston by using a C-clamp?

They come right out using a c-clamp. Use a short piece of pvc pipe or similar with an ID larger than the pin, set it against the piston, then use the c-clamp to press the pin right out into the pipe. Takes very little effort and no damage.

Cool. thanks, Ron

Usually the pin has been banging against the clip and raises a burr on the clip grooves. This is what you have a problem with. After you get the piston off, you can deburr the pin hole at the groove and the pin should then slide right through on assembly.

Jay

or you can get a small butane torch and heat the piston just until its hot to the touch....pin will slide right out..

I got them out the other day. Interesting explanation of the burrs on the clip grooves. I will check into this. It didn't even cross my mind.