Question about 2003 ATK 125 4-stroke

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Piston rings positions

I know where the oil ring goes. The other two rings go in which order? - They both look the same size, although one has a shiny edge.

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Hi johanjur
It is important that the rings all go in the right way up and in the correct order. The ring with the shiny edge may be tapered, the shiny edge then should be closest to the top. Check the rings themselves. There are often markings on them, and they generally face upwards. Hpethis helps you. Cheers
regards robotek

Posted on Jan 25, 2009


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The engine has blown. I need to replace it or change pistons and rings. How difficult is it to change pistons and rings?

It can be time consuming and the end result may not be desirable if you haven't done it before.
--- The following is just a sample of what to do once the engine is torn down: Pistons and Connecting Rods
  1. Before installing the piston/connecting rod assembly, oil the pistons, piston rings and the cylinder walls with light engine oil. Install connecting rod bolt protectors or rubber hose onto the connecting rod bolts/studs. Also perform the following:
    1. Select the proper ring set for the size cylinder bore.
    2. Position the ring in the bore in which it is going to be used.
    3. Push the ring down into the bore area where normal ring wear is not encountered.
    4. Use the head of the piston to position the ring in the bore so that the ring is square with the cylinder wall. Use caution to avoid damage to the ring or cylinder bore.
    5. Measure the gap between the ends of the ring with a feeler gauge. Ring gap in a worn cylinder is normally greater than specification. If the ring gap is greater than the specified limits, try an oversize ring set. Fig. 5: Checking the piston ring-to-ring groove side clearance using the ring and a feeler gauge tccs3923.gif

    6. Check the ring side clearance of the compression rings with a feeler gauge inserted between the ring and its lower land according to specification. The gauge should slide freely around the entire ring circumference without binding. Any wear that occurs will form a step at the inner portion of the lower land. If the lower lands have high steps, the piston should be replaced. Fig. 6: The notch on the side of the bearing cap matches the tang on the bearing insert tccs3917.gif

  2. Unless new pistons are installed, be sure to install the pistons in the cylinders from which they were removed. The numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore. If a connecting rod is ever transposed from one engine or cylinder to another, new bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number. The notch on the piston head goes toward the front of the engine.
  3. Install all of the rod bearing inserts into the rods and caps. Fig. 7: Most rings are marked to show which side of the ring should face up when installed to the piston tccs3222.gif

  4. Install the rings to the pistons. Install the oil control ring first, then the second compression ring and finally the top compression ring. Use a piston ring expander tool to aid in installation and to help reduce the chance of breakage. Fig. 8: Install the piston and rod assembly into the block using a ring compressor and the handle of a hammer tccs3914.gif

  5. Make sure the ring gaps are properly spaced around the circumference of the piston. Fit a piston ring compressor around the piston and slide the piston and connecting rod assembly down into the cylinder bore, pushing it in with the wooden hammer handle. Push the piston down until it is only slightly below the top of the cylinder bore. Guide the connecting rod onto the crankshaft bearing journal carefully, to avoid damaging the crankshaft.
  6. Check the bearing clearance of all the rod bearings, fitting them to the crankshaft bearing journals. Follow the procedure in the crankshaft installation above.
  7. After the bearings have been fitted, apply a light coating of assembly oil to the journals and bearings.
  8. Turn the crankshaft until the appropriate bearing journal is at the bottom of its stroke, then push the piston assembly all the way down until the connecting rod bearing seats on the crankshaft journal. Be careful not to allow the bearing cap screws to strike the crankshaft bearing journals and damage them.
  9. After the piston and connecting rod assemblies have been installed, check the connecting rod side clearance on each crankshaft journal.
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  6. Install any remaining components or body panels which were removed. prev.gif next.gif

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1 Answer

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Blower was used with motor oil gas mixture. Any

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2 Answers

I am changing piston and rings, my problem is that the ring are different, do you know which one go on the top, one is more black or dark than the oder.

Most rings are marked in one manner or another. They may have a dot on them, a angle cut on the inside towards the piston, or some other means of identifying which position it goes in and in which direction. If the two rings are different, there should be a paper to tell you how they go on the piston. Since you're asking this question here, I assume that this is not the case.

I'm not familiar with Suzuki DR-Z 250. In the case it's four stroke with three rings, two compression rings and an oil control ring. If the two compression rings are the same, no bevels, no dots near the end gaps, or other markings, I'd assume that they are the same. I would install the "brighter" ring on the top as it may be either a chrome ring or moly coated ring. Make sure you check the end gap clearance on the rings and do not align the end gaps, stagger them around the piston.

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2 Answers

After top overhaul my bike engine blow out excessive smoke and oil drip from exhaust manifold, what is the problem

Your problem is quite simple as what you done is rebuilt it with new piston rings i expect ,,but what you dident know is how to go about it SO what you have done is to fit the rings upside down ,,or ,,you have broken the new one putting it in ,,or,, you have got the wrong ring for the job,,or you dident hone out the cylinder the correct way and you took the lip of the cylinder but to much ,,or ,,the piston groove was to big alowing the piston rings to flap as it goes up and down,,and if 2 or 3 ring piston the ring gaps have to be (being air cooled) reset at 4 thou(.0004")(per inch per bore) and all rings have to be staggered,, 4 ringed piston stag to N-S-E-WEST,3 Rings in a Triangle 2 rings Opersit each other and 1 ring any where if the piston isent pined.
So let me know how you get on and work by the above and you will have a good bike again. Ron
New gaskets and (no goo ) to fit them on with and away you go
Let me know how you get on Ron

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