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  1. #1
    Nothing like getting air, while sitting in a chair VonnerNIX's Avatar
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    Piston Pin Stuck in Piston Head

    I am in the process of tearing down my 65U engine, in my '97 GP1200, and had a helluva time getting one piston out of the cylinder. After struggling for a bit, I managed to get it free and get the cylinders removed.

    I have taken the outer two pistons off of the crank arm (not sure of this term), but cannot get the middle piston pin to come out. I have taken both clips out, but the pin is stuck. As you can see there are some burrs on the end of the pin sleeve, but it is stuck before it even gets to that point.

    What is the best way for knocking this out? Should I use a punch and a hammer, or will that damage the crank?

    I was excited to be making progress, but seem to have hit a small road block.

    I am going to take the cylinders to get the middle one bored, but am still trying to source a new piston. Any suggestions? Shop doing the boring says they will sell me a Wiseco .5mm oversized for ~$150. Is this a good deal?


  2. #2
    Moderator OsideBill's Avatar
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    Need to get a piston pin puller for the bad ones. sometimes you can support the piston and tap them out this one looks pretty ugly though. Sand all the high spots out of the hole.

  3. #3
    Moderator OsideBill's Avatar
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    here is a link to oem piston sizes notice the three std +.25mm and +.5mm Pro-X make them even bigger. get matching rings if buying OEM, Pro-X comes as a kit with the rings.

  4. #4
    Nothing like getting air, while sitting in a chair VonnerNIX's Avatar
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    Thanks Bill. I have never heard of such a tool. I will look for one locally. I am also having trouble sourcing the flywheel removal tool, but I'll keep looking.

    Your 2nd post about the pistons doesn't contain a link. I will try to search the web to see what I can find.

  5. #5
    Stop staring at my tits NJJer's Avatar
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    This is what you need.


    IIRC it is made by Motion Pro.
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  6. #6
    Nothing like getting air, while sitting in a chair VonnerNIX's Avatar
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    Sprayed a little penetrant into the piston and it came out much easier. Now to wait for the new piston to arrive so I can start putting everything back together.

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