SUZUKIPictures of how I removed the pistons, then cleaned them, set the rings, and reinstalled the pistons on my 89-09 Suzuki GS500 motorcycle.

But first, lets pay some bills:

  1. Put bike on center stand. Removed seat, gas tank, and carbs.

  2. Removed Cylinder Head and Cylinder Block.

  3. Removed piston pin retaining circlip using medium needle nose pliers. Though it serves the same purpose, this is not a snapring, so no snapring pliers needed. The piston pin is also called a wrist pin or a gudgeon pin.
    wrist pin

  4. Sometimes the piston pin slides out easily, sometimes, not so much. For those difficult, not so regular days... Anyway, this is a piece of pipe, a bolt, a couple of washers, some wood scraps. Easy peasy.
    Wrist Pin Remover

  5. Before and after on cleaning the pistons. Same deal as cleaning the inside of the head, wire brush, WD40, and a flat screwdriver.
    before and after

  6. I chose to mark left and right on the pistons. I figured they might have worn into the shape of their cylinder, so I'll put the Right one back on the Right, and the Left on the Left.
    piston marked

  7. Both pistons are already marked for front, which definitely matters. The mark is circled, and on the left there is a cutaway for the intake valve.
    piston marked

  8. I am glad I have a Factory Service Manual. I am not sure it really matters how the piston rings are lined up, as long as all the ring gaps are not stacked. I hear that the honing marks cause the rings to rotate anyway. But basically the manual says start with the top ring facing the intake valve, then each ring down is 120 degrees further clockwise, 1/3 of a circle, both pistons the same (Thanks "badguy" for finding an edit).
    Factory Service Manual

  9. Piston goes back on, piston/wrist/gudgeon pin goes in (might have to use the home made wrist pin puller bolt). The wrist pin clip goes back in with the gap up.

  10. As I rotated the crank to let the second rod up so I could attach the piston, I noticed I had to be careful with the first piston because the piston skirt hit the engine case. I had to hold the piston going down with one hand while I rotated the crank with a wrench with the other hand while I took this picture with my other hand.
    no image

  11. Here are both pisons installed!

  12. Next I sold out to make 02ยข so I can fulfill my lifelong dream of owning a 1986 944 with blown head gaskets.

    But no minivans!

  13. Then I finished my beer.


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