Yup you can do it without ring compressor. You should bevel the skirt a little(Hoserize), this will help you set the jug over the rings, the jug will slide on with ease as long as the rings are set in the piston properly. If I remember correctly, I rocked the jug back and forth very slightly to get the rings to compress, while holding the end gaps with my fingers, just a little finageling. It is a bit tricky for one guy to do it for the first time but just take your time. If you feel that the rings moved a little during setting the jug over them, pull the jug off and do it again until you feel comfortable that the rings did not move. I practiced a couple times before I was comfortable with the installation.

Got your piston last night, the wrist pin was tight as hell their was some scaring in the wrist pin bore, scratches and gouges making it stick and tight, I had to go a little MacGyver and took an old wrist pin and put it in a battery drill on low with plenty of oil and lapped the high spots off so the pin now moves as intended, had to run 2 battery s completely dead to lap it in, oil is not very abrasive lol.

The gouges on the outside of the piston wont hurt anything once they are sanded and filed down I would not hesitate to use this piston in this condition the damage was only cosmetic, you didnt send the rings so I cant speak for them I would have to check them before I could give you the two thumbs up.

You will need to buy new circlips you can get them at a local shop or from rockymountainatv try this link
http://www.rockymountainatv.com/product ... icleSelect

Part# 1038410001 if the link don't work, they are 1.99 for the pair, if you order please order 3 sets I want 2 sets for spares here.

Also order me 2 sets of the clips for the Pilot they are 2.46 each pair Part# 1038410004

let me know the cost I will send you the money when I send the piston back.

The wiseco clips are a pain to install and are easily damaged so spares are a must!

Thanks

ok,thanks,glad to hear the piston is still usable
Ordered 4 prs of circlips for the ody,2 pr for you,2 for me,and 2 pr for the pilot,they are being shipped to you
Also just tracked the other package being sent to you,said it arrived in at 6:39 am this morning,so maybe you'll get it today,I'm anxious to see how those jugs are,sure hope they're what i was told

Cylinders are here UPS came early, not impressed with the packing don't look like their is any damage.

Not sure why they added peanuts to the box their is not enough their to do anything, only thing I can think of is people think packages set static during shipping like boxing it up and setting it on your kitchen table, not much padding is required, at UPS the first thing they do it toss your package 10' into the air and land it on concrete to break in the box for shipping, then it bounces up and down 100 times a mile while its on its way to be delivered where the UPS guy will just drop it on your front step from the waist (seen it done dozens of times) then claim it was not packed right lol in my case the front step is concrete.

See in the one picture how the head studs pushed through the cardboard? Take your old broke cylinder and try to duplicate that, see just what it takes to push them through cardboard, a few thousand bumps will probably do it, wonder if them studs are still straight?

Here is the first one out of the box. it looks like it suffered a nice death blow their is aluminum smeared all over the cylinder walls, I will clean it up and measure the bore, the bottom of the cylinder looks ok.

Cylinder two came with a piston, cylinder says Kustom Kraft on top, looks like it had the sleeve replaced, if Kustom Kraft did the sleeve your in luck I have never heard anything bad about his work and the sleeves he uses are said to be better than Honda's

Noticeable right away is the top of the cylinder is not flat, I will have to take a close look at this to make sure the liner has not shifted up, then lap it flat so the head gasket will seal.

More later after I clean them up and take a real close look at them, the piston is the older style with all the machine work done, their was no holes drilled in the piston so I will drill them.

I knew one was not in good shape,but the other one was suppossed to be bored out to fit the piston that came with it

Nice score... Now what am I going to do??? You will be smoking my arse regular like HeHeHe

Bored one looks good its set for .0045 clearance, I need to drill the holes in the piston.

The other one will need bored for sure I will try to get it in the boring machine this weekend and make a few cuts to see if the piston you sent can be used or not.

You need to remove your studs from your old cylinder so they can be used on the replacement cylinder, you can remove them by taking two nuts and locking them together then turning the studs out like a bolt.

haha,I wish
I just want to be able to ride this thing,I had about 25 minutes total drive time on it before it blew

I went thru the same thing... Mine was a ball joint on the front. While you are waiting go thru a lot of the maintanence and check every thing out and make sure it is to spec's... Keep in mind these are 24 year old machines that the previous owner might not have cared for as well... Now try to imagine your Chinese Buggy 24 years from now... NO COMPARISON!!! I am still working on mine, but at least when I am done with whatever I am fixing or upgrading I see and feel the improvement!!! I will let you know when I head to Houston. I just got the ok to race with the UTV at some of the MX tracks so I will be there soon!!!

I drilled the holes in your piston that came with that cylinder and its ready to go you want me to ship it tomorrow it might be several days before I can bore and hone that other cylinder.

I forgot to check on a ups pickup,if you can send it ups then go ahead,if usps hold off till I see if I can get a pickup,usps is twice as much as ups I do believe

also,did you get the circlips order? if so,don't forget to include mine with the jug,I ordered 2 pr for me,2 pr for you
thanks

Check into the pickup thing, its all how fast you want one back so you can install if I send one or both at same time.

Check into the pickup thing, its all how fast you want one back so you can install if I send one or both at same time.[/quote]

ok,I'm going to arrange a pickup,will somebody be at your house ? or do you want it picked up at your work?
where would you like ups to pick up at,front door,back door,side door,garage,etc,etc,they ask these questions on the website
thanks

ok,I'm going to arrange a pickup,will somebody be at your house ? or do you want it picked up at your work?
where would you like ups to pick up at,front door,back door,side door,garage,etc,etc,they ask these questions on the website
thanks[/quote]

Pick up at house at front door, far as someone being here it will be hit and miss, I can leave on the front porch no risk of it being stolen here lol I have done that before.

Pick up at house at front door, far as someone being here it will be hit and miss, I can leave on the front porch no risk of it being stolen here lol I have done that before.[/quote]

ok,Ive scheduled a pickup for tomorrow between 9 and 7,
thanks

ok,Ive scheduled a pickup for tomorrow between 9 and 7,
thanks[/quote]

PM me your shipping info again please..

Sending you the one cylinder, wiseco piston kit, spare cir clips for your other piston and cylinder.

I will bore hone your other cylinder and finish cleaning up that piston early next week if that's ok with you, still busy as hell at work and some other projects I need to catch up on.

PM me your shipping info again please..

Sending you the one cylinder, wiseco piston kit, spare cir clips for your other piston and cylinder.

I will bore hone your other cylinder and finish cleaning up that piston early next week if that's ok with you, still busy as hell at work and some other projects I need to catch up on.[/quote]

ok,great,thanks again

SUCCESS!!
well hot cylinder and pston installed tonight,it wasn't easy,took several trys but eventually got it on with no breakage.I havent tightened the 4 lower cylinder nuts yet because it was late and I'm not smart enough to figure out the formula with this wrench.Manual calls for 27-35 ft- lbs.My torque wrench is 15 1/2 " long where chart says to measure,can anyone figure out the formula for me as to where I should set my torque wrench at?
thanks

Is your torque thing a 3/8 inch drive? or the 1/2 inch size? Go find a good one that is small... The formula is easy so go get a good nights rest!!! Don't put the clutch on till you have them torqued!!!

His overall lengh is 15.5... the formula calls for the middle of the handle or center of grip!!!

Mine has an actual notch to measure from...

yeah mine too, my handle is just notched in so I set it at whatever and go to work. 30 bucks or so for a 1/2 in from northern tool when I got it.