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Old 11-07-2018
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Piston-in-barrel-first refit method

I know it doesnít sound like a big deal - heaps of you probably do it, but my mate Nate told me about this method & it worked a treat and Iíd never heard or thought of it before.

The Gas Gas 250 piston is a pita to refit into the barrel when itís on the rod, as compressing the rings enough while holding the barrel is tricky. It is much easier to insert the piston into the cylinder, then lower the whole shebang onto the rod.

The lhs circlip was left in situ, so I just had to line up the pin & insert through the little end bearing, refit the rhs circlip & drop the barrel on. Speaking of clips, the Gas Gas circlips are heaps easier than KTM/ĎBerg ones Iíve done before.

Great tip.
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Old 12-07-2018
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Yep, it's the easiest way for sure!
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Old 12-07-2018
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So do you just put a temporary block between the base and cylinder while you get the last clip in?

I like the sound of this, thanks for posting.
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Old 12-07-2018
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Funnily enough I've not had too many problems getting the rings compressed and guided into the tapers on the barrel.. Must be my petite office worker hands!!

Pretty sure the reason the ktm clips are harder to get in is that they are recessed further into the side of the piston. Harder to get the leading edge into it's groove and have the rest follow suit.
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Old 12-07-2018
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Quote:
Originally Posted by bigberger View Post
So do you just put a temporary block between the base and cylinder while you get the last clip in?

I like the sound of this, thanks for posting.
I had the clip & some needle-nosed pliers ready to go, so from the lhs of the bike I just held the barrel in place with my right hand, twist Ďn push with the left and the clip was in.

Spoke to TSP today - my head should be back after a re-cut to suit the bigger piston on Tuesday. Frothing to ride
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Old 12-07-2018
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Still waiting on mine... 😭
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