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I have the cylinder off. How to I remove the piston without removing the connecting rod? Do I need a special tool? Who sells it ?

na mate

remove the circlips with needle nose pliers (you MUST replace them with new ones)

then use a deep fit 16 or 18mm socket, thread some all thread through it with a washer and nut on the back, and on the other side use a 6-8mm deep fit socket backed by a washer and a nut. warm the piston with a hair dryer or heat gun, then use the nuts to push the piston pin into the deep socket. You don't need to push it all the way, just enough so that its clear of the little end bearing.

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you can buy a tool for hundreds or use this - if you need force youre doing it wrong

if you heat the piston enough often you can just gently push the piston pin out of the piston ... never tap it out!

  • Author

I will have to look again for cir-clips. I didn't see any in there. It just looked like a press fit, without clips....

There will be circlips,, some have a tang . others need prized up [by small driver] the small groove in the piston wall ,, then grab it with pointed pliers

  • 1 month later...
  • Author

I have the cylinder off. Where do I get parts ? I figure I need the next size up from factory for a new piston?. Any machine shop can bore the cylinder ?

At this point I strongly suggest you get a manual and read it cover to cover twice.

The part you need are easly obtaind from many other web sites by simply adding your make model and year.

Most machine shops can bore it but,,,,, find one who does mainly bike work and likes jap bikes.

  • Moderator

At this point I strongly suggest you get a manual and read it cover to cover twice.....

And learn some of the "magic" words!

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