Re-building top end

[sprint]

I will be putting the barrel and head back on my Z900A4 soon and would appreciate some advise.

1. Do you put the base gasket on totally dry or use some Wellseal or similar? Do you need to use any Bond around the oil ways or studs?

2. Similarly do you put the head gaskets on dry or use some other sealing medium as well? Do you need to use any Bond around the oil ways? Is the cam tunnel O-ring put on dry or should some Bond be used?

Gaskets supplied by Z-Power, so should be good.

3. Best way to get the barrels on? I don't have any clamps so it it possible to get the barrels on without them or does the lead on the bottom of the bores allow the pistons and rings to easily slide in? How do you support the pistons to keep them upright and do you try to get all four pistons in at the same time or do two at a time?

[chrisu]

I normally grease the base gasket both sides

Grease should hold the tunnel gasket in place. If not the a bit of black silicone will

I use two fork shaped bits of MDF to hold middle Pistons straight

Will post a picture later

[Ginger Bear]

Like these Chris?



Drawing is from Joe Hooper & just happens to be sat on me desk.
Never used 'em before, but I plan to this time round.

[Ginger Bear]

I like the cheap & cheerful drainpipe ring compressors + plenty of lube method.
A method refined from Piggy's even cheaper plastic bottle method.

Doesn't suit everybody...... Make sure your pipe is de-burred thoroughly.

[weaver]

you can buy piston ring clamps cheap enough,I used two of these,

http://www.ebay.co.uk/itm/Sealey-Motorc ... 56665c732f

I do two pistons at a time,they do not slip in easy without something compressing the rings

[chrisu]

Like these Chris?



Drawing is from Joe Hooper & just happens to be sat on me desk.
Never used 'em before, but I plan to this time round.

well done - saves me a job.....

[ZedHead]

Plastic drain pipe makes great ring clamps

[sprint]

Thanks for all the replies and advice.

[sprint]

A 3" drain pipe is very nearly the same size as the piston. So have cut off some lengths about 15mm wide and with a cut down the side and a cable tie it compresses the rings OK.

Have done a dummy run with a piston and barrel on the bench and it sides in nicely, as they say.

Just got to decide if I do a couple at a time or try to get all four in one go?

[chrisu]

set the middle 2 at the top - using the fork shaped bits of MDF to hold the pistons square to the barrels

Then rotate the pistons and drop the barrels at the same time

you can then do the outer 2 pistons.

[Taffus]

This is one of those jobs that's done in a few minutes or takes forever
I tried a number of ways
pot noodle tops...didn't work for me though has worked for others
Drain pipe.....nope
I then bought 2 of These
These worked a treat, I was fitting 1170 so the chamfers at the botton of the liners were pretty non existent

I did the inner pistons at tdc then turned the engine so the outers rose and then did them.
I got to do it twice as I left the bloody cam tensioner blade out......DOH!

[Big Fluff]

Like these Chris?



Drawing is from Joe Hooper & just happens to be sat on me desk.
Never used 'em before, but I plan to this time round.

I made some too.

[sprint]

By using the 'drain pipe' trick on the pistons and cutting some installation blocks to support the center pistons the barrels easily slid over the center ones and after removing the clips from the center pistons it was possible to push the barrels over the end pistons.

[Ginger Bear]

Happy days.