top end rebuild??? HELP!!!!!!!

[rs_junkie]

hi lads,

right im quite mechanically sound as i do car body repair and very competent and need a quick run through in leighmans terms how to do a top end rebuild

got an rs and the fuckin thing went bang last weekend after looking at it it needs a new top end, I fried the piston rings and theyve grab the side of the bore and not getting any compression

iv bought a new piston piston rings gurgeon pin circlips top end gasket kit and new barrel (just gonna use my old head) and new spark plug (obvs)

now when i lift up the tank it looks easily accessable to do the job in place, i take it i wont have to rip the engine out the frame??? dunno

iv dun a bit of reading up and im pretty sure im confident i know what im doing but wanna clear a few things up before i go ahead and strip it as this will be my first 2 stroke engine rebuild

i know the basics circlips ends face down piston arrow faces exhaust port piston ring ends face inlet and gaskets need to be square and you need to stick a bit of 2 stroke down the bore before sliding over piston and torque down to 30NM and drain coolant before (obvs)

is there anything else for example sealant round gaskets???? or piston neds to be placed at a certain height (i wouldnt have fort so being a 2t single cylinder with no timing involved)

any help would be handy cheers rs junkie!!!
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RS JUNKIE
- 2001 black x reg rs125 - k & n airfilter - 34mm carb (upjetted)-
- Vertex Flat Top single ring race Piston - pmtuning twin exhaust-sprockets 15/42

[Kickstart]

Hi

It is pretty easy. Gentle afternoons work.

Take off the tank and fairing panels. Take off the exhaust. Unbolt the airbox and unclamp the carb from the inlet. Putt the carb and airbox back. Unbolt the bracing piece across the frame from the barrel and from the frame rails. Drain the coolant. Remove the battery, unbolt the battery tray and remove that. Unbolt the power valve housing and pull it out.

Remove the spark plug, unbolt the cylinder head cover and then the actual cylinder head. Unbolt the barrel and slide it up.

Put some clean rags in the crankcase mouth to stop anything dropping into it.

Clean off all the remains of gaskets. Remove one circlip and remove the gudgeon pin and then the piston.

Put one circlip in the new piston. Lube the small end bearing, put it in place, put the piston in position, slide the gudgeon pin in, put the other circlip in place.

I use a thin smear of grease on normal gaskets. Put the bottom gasket in place. Make sure the piston rings are in the right position (there are locating pins to keep the rings in position). Use your fingers to compress the rings into their grooves and slide the barrel down over the piston. After that it is pretty much the reverse of disassembly.

All the best

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

[Raf]

Lol at the neatly cut out "L"
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CBR1100xx - BMW K1100 - BMW K100 - Triumph Sprint ST 955i - Suzuki GSX-R 600 - Suzuki DR 350 - Yamaha XV 750 - Honda CBR 600 FM - Yamaha XT 600 - Yamaha Rs 200 - Honda NSR 125