removing piston circlips

dont forget to shove some rags in the holes in cases below pistons while removing or installing.

650ed wrote:

Use one of these to cut the piston and wrist pin out of the way leaving behind the undamaged circlip. :woohoo:

then you can use one of these to clean up smallend of rods,always remember to first remove sawdust/woodchips from plumbing project before using on motor! :woohoo:

Are the clips on bigger motors ( a 900 for example ) much more difficult than a 650? I removed the pistons/clips from a 77 kz650 with no problem. Use my scriber. No bends or kinks. The clips went back in ( on the bench ) no problem. I plan on rebuilding my 76 kz900 next winter. What can I expect?

Thanks,

Ross

don't reuse the clips order new every time they come out as they will lose tension and distort not worth wrecking a motor over 1.50 worth of parts. the clips usally arent that bad to remove but make sure you stuff rags or paper towels down in the cases so they won't go flying into the bottomend.

I know this has been answered and this thread died 6 months ago, but I have an idea that might help. Curiously, I have a tool in my toolbox that looks like the pincher surgeons use to close off spraying blood vessels.

It has two tiny jaws and it locks in place when you close it down, so it's able to wedge under the circlip and then lock onto it, so it doesn't shoot out your eyeballs. Worked like a charm for me.

called a hemostat and yes they do work well for holding onto small things like circlips.bj

I found the circlip! :huh: :laugh:

Hemostat's come in several sizes and shapes. You can get them at most medical supply shops or bigger pharmacies. I use the ones with the curve in the tip. Usually the clip can be rotated in the piston with a small tool, so if you rotate it so the ends are at 9 or 3 o'clock, it's easier to get a grip on them. I never had a problem with it, although they are a tad harder to put in then get out. I did drop one in the case once, and it took some time with a magnetic rod to fish it out, so I highly agree with stuffing rags in the holes!

I've reused them after re-spreading them a tiny bit and never had a problem, but I agree that new is better.

Id like to add my 2 cents since I spent a few hrs this summer with the SOB clips!! Yes the weisco clips are killer tough on the fingers!!

Getting them out is easy. Always used new ones! Here is a trick I used to put them back in!!!

Put one in on the bench on the remaining one push the closed end of the clip into the hole in the piston. The clip will compress and continue into the hole. once it is stuck inside push one end in and then the other. Works like a charm takes a bout 1 min once you get the hang of it :woohoo:

Now that everyone has this under control, who has been using Teflon buttons in place of the cir-clips?
Anybody??? Racers????
Or maybe use a different press fit assembly???

I always orientate the clip so that the open end is at the bottom. I read this many years ago in a Dirt Bike Rag, seems the clip takes some forces as piston & rod change direction. Some believe it could lessen the chance of it popping out if the opening is NOT 90 degrees to the rod.
You guy's remember some of the wire one's that had the bend on one end so you could grab it with a pair of pliers?? I wonder if those had to much inertia on the heavier end,I haven't seen any for quite a while.
What ever you do use NEW.