Step by step procedures for piston and ring replacement

[bluemonster1]

Maybe someone on here with the knowledge and expertise can write up with pics in the Tech Section the exact procedures from A to Z on piston and ring replacements. They can offer some of us unexperienced TY'ers in steps and pics how to dismantle the top end properly and how to replace the piston and rings and then putting everything back together again with the correct specs and checks we have to do in order that when we start our engines,things don't fly apart.Tried this when I was young on my old 78 T.N.T 440. Didn't drive to long and the piston blew on me again. The sled went into the scrape after this.Went and bought my first Yamaha sled after...440 Exciter.Then an SRX 440...Yamaha Tri-moto.....Yamaha 700 Maxim....and the SXR600...soon to be another SRX(2001) which I am still shearching for.Yamaha all the way for me man.

 

[FuzzButt]

It's really not that hard unless you feel complelled to change the rod or the rod/crank bearing. As long as the clearance is in spec I have not had an issue with my top only rebuilds. The manual goes a long way toward helping but most of the info is here. I think the biggest issue doing a writeup is the fact that there are many differences in motor design between the Twins and the Triples and the triples with the power valves, I have only done the twins.

Having confidence and the right info and tools before you start helps a ton.

When I did my 600 it was my first. I had it apart and needed almost 3 weeks before it was back together again. Getting all the parts ordered delayed me and having detailed pics and instructions helped get it back together withour any extra parts. 2000 miles later and still going strong. My second motor was a 2 hour job start to end.

If I do another this year I'll make sure I take good pictures and document.

 

[bluemonster1]

A lot of things you do for the first time is always difficult,but second time around is always easier.Have done everything on my sled so far myself,changed track,removed suspension, r&r all bearings from front to back.Had all the front end apart ,clutches apart numerous times...etc.Tearing apart an engine top end doesn't sound to hard,but going further to the bottom end I would hesitate a bit,but would like to learn you know.If I had to go the dealer everytime something had to be changed or added,I would be so broke by now that I probably wouldn't have food in my cupboards or any gas for my vehicles.LOL.

 

[FuzzButt]

I refuse to go to a dealer except under conditions of last resort. It sounds like we share similar repair experiance.

Being someone who fixes things for a living I like to be hands on for the rest of the things in my life. Jack of all trades in a way.

 

[BLUEBALLER]

I finally did the top end my 700 last month. 15000 kms and I figured it was time to have a look even though compression was still approx 110 on all 3. Not really a big deal at all. I too have done everything on this sled except bottom end. I will save that for when I need a reason to tear into it. Seeing as this topend was my first, I'm by no means an expert, and I actually found it to be a lot easier than I originally thought. Pay attention to the small details(piston arrows, ring markings, don't drop anything into the crank) and you should be fine. Use lots of oil when putting it back together so you don't score anything and it's a piece of cake. Over 120 psi across all 3 now and I put 56 kms on it last weekend ripping around my yard. I changed my clutch setup now so I'm fine tuning that. Splitting the primary to change the moveable bushing was much more of a bear than doing the topend IMO. If you have any questions while you doing it, just post em here. I've found that with these forums, there's nothing I won't tackle on my own.

 

[xt700]

ive said this already but here goes when attempting something new grab a pen, paper and digital cam. take notes of what you did and plenty of pics of what youre doing. when youre putting back together,its everything backwards if youre stumped take a look at the pics to refresh youre memory. if all else fails hop on here and ask for help.
good luck
Pat