Cylinder Re-installation

[bettingpython]

Ok I have my wifes bike apart for new gaskets and am wondering how hard it is going to be to reinstall the cylinders? I have never done pistons without the usage of ring compressors before but according to the manual you just have to squeeze the rings together as they go in. Has any one done this?

[hmmmnz]

not on the gs but on other bikes,
it was just as the manual says, squeeze them as they are going in, no bother at all
have fun

[bettingpython]

  Thanks Hmmmmmmz

[dgyver]

Yep, stock cylinders are easy to reinstall. There is plenty of lead-in chamfer. Ring compressors are not needed.

When you start increasing the bore, the rings are more difficult to fit in the cylinders since there is less chamfer the assist. Still possible without a compressor.

[scratch]

Pretty easy, go slow. 

[bettingpython]

Pretty easy, go slow. 

Well I snapped a damn ring got impatient.

I should have 3 extra base gaskets when I am done my parts order was messed up and the restocking thing is not worth it for these gaskets. As the wife progresses I will wind up getting her a 600 I4 or VFR so I shouldn't need to get into the motor again and will gladly make anyone who needs to do gaskets a good deal. Anyone have a set of rings laying around they could fed-ex to me?

[facepants]

Having fingernails helps.

[ducati_nolan]

Yeah, might be worth getting a compressor to prevent breaking the second set.

Don't forget to hone the cylinder for the new rings. Good luck 

[dgyver]

Breaking rings typically happens when installing the rings on the piston, not installing the pistons in the cylinders (unless you force the crap out of it). There is a tool to assist in opening them up.

[bettingpython]

It really did not feel as if I were applying any force when I snapped the center ring on the number 1 piston. I begin to suspect that I may have discovered a point of failure, a weakened ring, and may have saved myself a headache down the road. Just glad it didn't fall into the cases. I have the number 2 piston higher than the number 1 piston and when I slipped the cylinders on that side it went really easy, as I started working the cylinders down over the number 1 piston the top compression ring slipped in like it was buttered the center ring was acting hinky and when I gave the cylinders a little wiggle to work them down over the ring the end of the ring came flying off into my face. Just a reminder to those who do their own work no matter how inconsequential the job you are doing may seem wear your safety glasses.

[3imo]

Python-
  where'd you get your gasket kit and piston rings?  I know of a few places, I am just interested on what you got, how you got it and how much of your arm and leg did they take.

I am in the market for some gaskets, whatcha got and how muchya want?

[bettingpython]

3,

I bought all of my gaskets from http://www.ronayers.com they seem to have about the best prices around on oem parts. I didn't buy a kit I simply identified all of the gaskets, seals and o-rings I would be replacing using the online parts fiche and ordered everything I needed. I think I paid right around 100 bucks including shipping all total. They are not the fastest but very dependable. This did not include rings as I had no intention of rehoning and ringing the pistons when I set about starting this project it's intent was to fix about 5 minor oil leaks.

Good luck with your projects.

[ducati_nolan]

I saw a gasket set on ebay for $30 I think. They pop up fairly regularly and I think they are up for auction right now. Not sure about the quality but much cheaper than $100

[bettingpython]

I assume your talking about something like this.

http://cgi.ebay.com/ebaymotors/NEW-GASKET-SET-SUZUKI-GS500-ALL-YEARS-GS_W0QQcmdZViewItemQQcategoryZ35595QQihZ002QQitemZ120091755923QQrdZ1

Looks like seriously cheap knock offs to me.

Remember ron ayers screwed up and sent and charged me for 4 base gaskets At $5.07 a piece that was a $15 mistake. But no biggie like I said I will offer them at Ronayers price to any GStwin member who needs one and shipping will be standard first class mail.

The base gasket in that set appears to be cork or cardboard a oem gasket is steel with a thick sealent coating. Same for the head gasket shown although it may be steel it appears flimsy compared to the one sitting on my work bench.