Piston bodgery (chipped skirt)

[stinkwheel]

So, if I fit this to the GPz305, will it bring about the end of the world as we know it?

https://i48.photobucket.com/albums/f216/stinkwheel/305/Image038.jpghttps://i48.photobucket.com/albums/f216/stinkwheel/305/Image039.jpg

I chipped it on the edge of the crankcase by turning the crank with no barells on.

Should I do the other side as well so it's the same (lots of filing!)? I presume I'll need to do the other side piston the same.

I can't think why it shouldn't work, after all, the piston skirt wouldn't come into contact with the bore under normal useage.

I'd buy a new one but Kawasaki want £80 for it! Not that I can't afford £80, it's just general principle. £80 is about 4 times what it's worth and I'm not paying it unless I absolutely have to.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Kickstart]

Hi

Personally I wouldn't use it. Think that it would touch (although not hard), and it just doesn't feel right.

£80 is a fair amount for a piston. Suspect there must be a fair few floating around dealers as new old stock items.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[MaybeGuy]

if you file a very smooth, progressive chamfer then i dont see why it wouldnt work. just make sure you eliminate every trace of a sharp edge.

i know you shouldnt on anything to do with engines reall, but emory cloth/wet and dry could help with that.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!!
Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

[FerretFing]

For the sake of £80 it`s not worth the risk - get a new one!.

OR

get BCF to have a whip round for all the help you give & threaten to leave the forum

[stinkwheel]

If I have to spend £80 for a single piston, the whole engine can go in the skip and I'll sell the rest of the bike as a job lot of parts.

Whole, running bikes change hands for £300 or so.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Kickstart]

Hi

Suspect a short wait and you will fine another piston attached to a trashed engine for a nominal amount of money.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Thom]

i say try it!

if you dont wanna buy anyother and are willing to skip the engine anyway why not see how it goes?
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Current Bike: 1996 Yamaha TRX850 (The Japanese-Ducati One).
Previous Bikes: 1990 Honda NSR125 'Rothmans' (The smoking one), 1990 Suzuki GS500e 'Caf? fighter' (The loud one), 1987 Kawasaki GPX400r (The quick one), 1997 XJ600s Diversion (The reliable one), 2000 Kawasaki ER-5 (The spontaneously combustive one)

[Pete.]

I agree if you're gonna skip the engine then stick it in and see how far it goes.

Looks like the combustion-gases have been held back by the oil-control rings anyway
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[stinkwheel]

Well, they're in. I did both the same.

I shall endeavour to make a recording of the first starting attempt.

Got the timing bang on first time too.

If the engine eats itself, I may be on the lookout for some alternative pistons. Maybe see if a couple of Honda 350 ones or some Z650 would fit with a bit of machining. I've got two sets of scored barrels anyway.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[LanaTheGreat]

So how did it go?

[stinkwheel]

Aint tried it yet. Engine is sat here ready to go into the frame for a quick try. These things have a habit of taking longer than you'd think.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[stinkwheel]

Engine runs. Started first push of the button. There is a big hole in the middle of the rev range. I reckon this is air filter/airbox related.

Unfortunately it's pishing oil out past the head gasket so I've had to strip it again. Annoying bacause I did that bhit properly. I even polished the mating surfaces on a sheet of glass. I'm putting it down to a cheap shite head gasket. Might try to make one out of copper instead.

Here's a short and crappy MP3. That is literally the first attempt at starting after I put the fuel tank on. I cranked it over a fair bit with no fuel in to start with the get the oil circulating.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[LanaTheGreat]

You might as well check if the piston did any damage to the sleeve etc since you did run the engine for a while.