How to..

can some one please tell me the best way to get the pistons back into the cylinder block .i have the cylinder block removed the the pistons off the rods. i need to assemble the engine again. any tricks/ tips will help.

You will need ring compressors or maybe some large hose clamps. If you have some friends with strong hands, they may be able to compress the rings as you drop the cylinder.

If they are used pistons and pins, you may need a pusher to get the pins back in the pistons. Use new spring clips for the pins.

well now that i kind of trashed the gasket i had laid down ill have to wait for a new one. so your saying with the rings compressed say with a large hose clamp just kind of do one at a time? anyone have any other ideas?

Someone a little while ago had suggested putting each piston into the block separately....... and then connecting the lot to the crank arms. Seems like it could work, not much room for fingers though

bluezbike wrote: Someone a little while ago had suggested putting each piston into the block separately....... and then connecting the lot to the crank arms. Seems like it could work, not much room for fingers though

Not sure I would try that one on a KZ engine. Done it on a car.

Assuming we're talking about a 4-cylinder engine (?) it's easier to install the two inside pistons first.

Install the base gasket and whatever o-rings, cam chain guides etc. you have there.

Rotate the crank until pistons 1 and 4 are all the way down and 2 and 3 are all the way up.

Insert wooden supports between the base gasket and pistons 2 and 3 (I made the supports pictured below in like 5 minutes) and rotate the crank until pistons 2 and 3 are resting against the supports and are as centered as possible.

Apply a thin coat of assembly lube or engine oil to the cylinder bores, slide the cylinder block onto the studs and insert the top of pistons 2 and 3 into their bores.

Compressing the rings with whatever you need (I've never used anything but my hands) gently slide/wiggle the block down over the rings - remember to space the ring gaps 120 degrees apart.

Once you have pistons 2 and 3 installed lift them off the supports by rotating the crank and remove the supports.

Rotate the crank so that 2 and 3 comes down and 1 and 4 comes up and repeat the above for pistons 1 and 4, there you go.




Edit: Btw, when installing the piston pin clips, DO NOT forget to stuff rags or whatever in the case holes around the rods, clips down the crank case is not a good thing. :whistle: :pinch:

Ive used wide zip ties. Ive also used popsicle sticks. But perfer the large zip ties it had it allot easier. but other than i used onkelbs instructions.

Some folks use thin metal strips under the zip tie, whereby both slide down as the rings enter the bore.
The strips may be cut from an aluminum can.

Be extra careful with the oil rings, to have them properly fitted without overlap, and not damaged during the during the installation process.

Have never been fortunate enough to own the real McCoy:



(Above compressor is for Z1.)

Good Fortune!

On my twin, I just used some 2x4 blocks to hold up cylinders and then used my fingers and wood sticks to press in the rings.

I use the NAPA ring compressor instead of messing around and breaking the oil rings.

No eBay APP ID and/or Cert ID defined in Kunena configurationYou could buy this and then sell it again on eBay after rings are installed. You probably would be able to break even on cost. Ed

bluezbike wrote: Someone a little while ago had suggested putting each piston into the block separately....... and then connecting the lot to the crank arms. Seems like it could work, not much room for fingers though

That's how I do it.
Insert each piston into it's cylinder, lower the block onto the connecting rods, insert wrist pins and retainer clips.
Do the pair in the middle first, then rotate the crank to bring up the outer pair.
Yes, it's tricky, but it works.

Here... kzrider.com/forum/11-projects/206149-fre...g-up?start=60#229596