Engine case assembly

[jasowiii]

Anyone have experience assembling the left side engine case onto the rest of the motor? I am working on a '83 GL1100 and not having much luck getting the left side, cylinders 2 and 4 to over the pistons/rings. I have watched the video on the how to section and it looks easy. If you watch the whole series that dude makes everything look easy. Maybe in Australia they reassemble Goldwing engines in 30 minutes but not me. I guess the "down under" thing helps the pistons fall UP into the cylinders.

Anyway, the honda repair manual (pg 8-21) makes no mention of using hose clamps to compress the rings, The cylinders have a pretty good lead in chamfer on the crank end. I've done quite a few 2 strokes that have a good chamfer and have always been able to just squeeze 'em together. I guess they also have "skirts" that let you pinch the rings while you wiggle the piston in.

I am thinking about trying put it together w/o hose clamps and maybe I can reach in w a pop sickle stick or something soft to "massage" the rings into the chamfers.

Thoughts?

[joecoolsuncle]

https://www.amazon.com/Cal-Van-Tools-64 ... 97e41410bb

[Rednaxs60]

Having had my 1200 engine cases apart several times, I can sympathize with you. There is a piston support block that is quite useful, I ordered one and made the second. Orients the pistons correctly for install:

There is a Honda piston ring compressor that makes the job very easy:

I did use a hose clamp:

. This clamp was not bad.

Getting the clamp or ring compressor out is a test of patience, not a lot of room.

[jasowiii]

Ernest,
Thank you very much for the detailed response.

I think my biggest problem is my clamps. One has a large drive gear thingy that is causing it to tip/bind. I was thinking about making something like the honda piston ring compressor. Can you tell me what the "wall" thickness is and does it have an angle/chamfer at the top?

I am using rectangular wooden blocks as piston supports (1.5"x2"x3") with the 2" setting the height of the piston. The protrusions (had to spell check that one) and the curve on the honda tool makes me wonder if I am missing something. In case I (or anyone else) make spacers too, is there a chance you could share dimensions?

I see you are in BC. I enjoy riding up there every chance I get. Mostly ADV but I did take my wing up just before Covid. We did not realize it was Canada Day weekend so traffic was knarly but we ended up staying at Toad Rock campground near Kootenay Lake. Wild!

I got this bike for free. 4th gear was out and the guy had dropped the motor and ran out of steam. I replaced the center shift fork (bent) and the associated gears and am now reassembling. My plan is what I call a "Honduro". Basically a big dual sport.

Thanks for the help,
Jim

[Rednaxs60]

The clamps I used in my pics worked well but are not as good as the OEM ring compressor. Doesn't matter what you use, getting them out is a test in patience. using the ones I did, you should replace the nylon nut on the tightening screw. Will scan in a pic with dimensions. The OEM support works very well and makes life easier.

[jasowiii]

Success! But it was not easy. 11th try was the charm...

Ernest, If you do have time to share dimensions for the piston support that might help someone in the future. I agree it turned out that the support was more important than perfect clamps or ring compressor.

I'll share my story in case it can help someone else.

I made some really cool ring compressors out of 3" ABS pipe. I think it was attempt #7 when we figured out they were too tall and hitting the wooden blocks we were using for piston support. So we ditched them and used standard hose clamps for attempts 8-11. If I were to do this again I would make new compressors out of ABS pipe but I would make them just slightly taller than the clamp.

The large blocks could not be removed once we got it assembled so we disassembled (#9) and cut a block in half and trimmed the length. Final dimension was 1/2"x2"x2.75". The trick is once you get the pistons started you tip the support out from under the piston and wiggle it out through the gap in the cases. Too big no worky. We put rags around/below the spacers to keep from losing them. I would drill a hole and put a string through it if I do this again.

I did end up using only the cheap hose clamps as compressors because I had help over and we were determined to figure it out that afternoon w what we had on hand. I think it was attempt #10 where one of the clamps got stuck (maybe in the wrist pin relief feature) and resulted in another disassemble.