Piston Installation - Yamaha V star 1100 Owner's Manual

124
the homemade tool shown in Figure 119. Do not
drive out the piston pin. This could damage the pis-
ton pin, connecting rod or piston.
6. Remove the piston from the connecting rod and
remove the remaining circlip from the piston. Dis-
card both piston pin circlips.
7. Mark the piston pin and piston so they can be re-
assembled as a set.
8. If the piston is going to be left off for some time,
place a piece of foam insulation tube over the end of
the connecting rod to protect it.

Piston Installation

1. Apply fresh engine oil to the inside surface of
the connecting rods.
CAUTION
Install new piston pin circlips during
assembly. Install the circlips with the
gap away from the cutout in the pis
ton.
2. Install a new piston pin circlip into one side of
the piston. Make sure the circlip end gap does not
align with the notch in the piston (Figure 120).
3. Apply fresh engine oil to the piston pin, and in-
stall the pin into the piston until its is flush with the
inside of the piston pin boss (Figure 121).
4. Place the piston over the connecting rod (Figure
111). Make sure the EX on the piston crown (A,
Figure 122) faces the exhaust side of the cylinder.
This is the front side on the front cylinder and the
rear side on the rear cylinder.
CAUTION
When installing the piston pin in Step
5, do not push the pin in too far. The
piston pin circlip installed in Step 2
will be forced into the piston metal,
destroying the clip groove and loos
ening the clip.
5. Line up the piston pin with the hole in the con-
necting rod. Push the piston pin through the con-
necting rod and into the piston boss on the other
side of the piston. It may be necessary to move the
piston until the piston pin enters the connecting rod.
Do not use force during installation or damage may
occur. Push the piston pin in until it bottoms against
the pin clip on the other side of the piston.
118
119
Pad
Nut
Piston
Piston pin
pin
120
End gap
6. If the piston pin does not slide easily, use the
homemade tool (Figure 119) used during removal
but eliminate the piece of pipe. Pull the piston pin in
until it stops.
7. After the piston is installed, recheck and make
sure the EX on the piston crown faces the exhaust
side of the cylinder.
CHAPTER FOUR
Nut
Washer Threaded
rod
Pipe
Notch