- 1). Clean the piston thoroughly with a wire brush and carburetor cleaner. This includes the piston ring grooves and the top of the piston, which might have excess carbon buildup on it. Use a ring cleaning tool to clean the piston ring groove passages. Adjust the ring groove cleaning tool to the proper bit for your ring groove. Cinch the tool over the piston and make a few complete rotations around the piston skirt. Clean the other ring grooves in the same manner.
- 2). Lubricate the inside piston pin bore with oil. Dab the inside bearing surface on the small end of the connecting rod with oil, making certain that both bearing sleeves sit tight inside the top of the connecting rod. Fit the piston pin into the piston pin bore and place a small, deep-well socket over it. Tap the end of the socket with a hammer, driving the piston pin inside the pin bore, while aligning the top of the connecting rod (hole) with the pin. Drive the pin all the way through until it seats on the other side of the piston.
- 3). Place the bit and guide of the ridge cutting tool on the inside lip of the cylinder bore at the extreme top. Adjust the tool and connect a socket and wrench to the large bolt on top. Turn the ridge cutter several rotations to cut the excess lip at the top of the cylinder. Wipe the cylinder bore clean.
- 4). Use 180-grit sandpaper to scour the inside surface of the cylinder bore. Sand vertically all around the cylinder bore then switch to horizontal sanding strokes. This will create a crosshatch pattern and allow the rings to seat. Clean the cylinder bore with carburetor cleaner and a rag.
- 5). Slip the piston rings onto the piston by hand, starting with the lower ring. Gently pull the ring apart and work it down over the piston skirt until it seats into the groove. Install the other ring (or rings) in the same manner but face the ring gaps 180 degrees apart. Smear oil inside the cylinder bore.
- 6). Place the ring compressor sleeve over the top of the piston, covering the piston rings. Use an Allen wrench to cinch the sleeve tight over the piston, compressing the rings. Drop the piston down through the cylinder bore, making sure to align the connecting rod to the crank shaft journal so it will bolt on correctly. When the ring compression sleeve stops at the top of the cylinder head, tap the top of the piston down into the cylinder with a rubber mallet. Remove the ring compressor sleeve.
- 7). Attach the bottom of the connecting rod journal to the crankshaft journal. Make sure you first install the bearings inside the lower, large end of the connecting rod and oil them. Fit the bolts into the connecting rod cap bearing and tighten the bolts to manufacturer's specification with a torque wrench.
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