hello guys i have some ansewers befor i reassemble pilot topend ok in serv manual pg 7-0 shows only two dowl pin on cluch side of eng on page 7-4 it shows two my eng only had one in front left i got this pilot new never been torn down till now . what is a good ring gap im at .20 over my ring gap is .330mm book does not tell what is too small only too big page 7-6 please help me my son wants to ride

on 7-0 it shows one i ment to say. piston ring gap limits

You only need 2 of the dowel pins on one side as shown by the arrows on page 7-4

Page 7-6 service limit on the rings is .028 in
Page 7-1 "Standard" .018 to .024 in meaning the new rings gap should
fall into the range of 18 to 24 thousands if tighter than .018 you would
want to file them down until they fell into the range.

"please help me my son wants to ride"

don't get into a hurry, take your time, triple check everything!

thanks so much guss i should use a jewlers file to remove .005 inn the relif on ring should i file that in as well ? .0025 off ea side

Yes a small file or dremel is a good way to adjust the ring end gap.

just had it bored .20 over wanted to know the correct ring gap thanks and if i had to also file in ring relif for ring stop on piston

thanks ive got a good dremell with vari speed control dident think of useing that tool that

pic showing the proper way to measure the ring end gap is on page 7-6 of the pilot manual just to make sure you are getting everything measured right. Go easy with the dremel, you can remove a lot of material fast!

What is your current ring gap, you said .20 I figured that was a type O and you
meant .020 if it is in fact .20 that is 200 thousands not 20 thousands then you have
the wrong rings that is about .180 too much gap! BAD!

If you have .020 gap you don't need to file grind or adjust your rings
because your in the allowed 18 to 24 thousands or .018 to .024 range.

Follow me?

Go put your ring back into the cylinder and measure the gap again with a feeler gauge
look at the writing on it and see if it is .020 ?

i have compleated checking and very careful at useing jewlers file to get ring gap of .018 this was very slow going but i got it going to assemble on tuse after work waiting for honda topend gasket kit got new ex ring and new springs and ready to do psi test when assembled ? what psi do i test at for any leaks &how long should it hold for thanks for all the help

I test to 8-10 PSI and it should hold for 15-30 minutes.

I never had to file the rings they always fell in the factory spec, I attached a picture
that shows you what it should look like when your done.

went down and got 2 new sets of rings and were with in spec assembled motor (( Internal Combustion Engine ? )) after work to day got good leak test im in nevada north of reno was 38 deg. when i fired up the new rebuild i am running a pkw39 mm main jet 165 with didgtron & had it ported pollished head pollished new exhust ring and springs with torque pipe & shorty silcencer this thing click starts pops good ran it about three minn sounds great i found that plastic putty knife works great to do ring comp when install cylinder . thanks everyone this board came in great help to me. ive been running red line in my pilot for 6years at least at 40:1 i had no carbon build up in pipe or export did have some on the exflang had to pollish that after soking it in carb cleaner for two weeks will always run redline oil my main bearings looked like new as well as the cases crank rod my pilot had warn out rings and one failed it went out the pipe found nothing in cases im running stock clutch with white spring this thing was fast befor never beat it to hard got 4 fox adj resevor shocks this pilot kicks ass ipt hole shots all the way around i love my pilot thanks so very much everyone

how about some pictures

will post as soon as i get a digital camera took pilot for short ride 10 minn running 165main jet my temp was at 1187 at half throtel going to 172 want to run rich till broke in in most cases with my old eng step up a jet size drop temp 35 to 45 degs. depending on weather and elv.