Tricks to install 1100 cylinder block over pistons/rings?

[vwztips]

Have rebuilt many Polaris 2 strokes with single cylinders. No issue getting the rings compressed for that.

Trying to a 3 cylinder block over the 3 pistons. Is there any recommended tricks short of 6 hands?
How do you hold the cylinder block and align pistons as same time?

I have seen some compression kits on ebay that should work. I assume all 3 pistons would need compressors at same time?

Thanks!

[steve45]

It can be tricky, but it's a lot easier on a Kawasaki than on a Yamaha!

You don't need ring compressors, just 3 large hose clamps. Make sure you check the ring gap, then have the rings on in the right direction and aligned with the pins. Put the hose clamps on tight, then slowly loosen them until they can move up & down on the piston. Turn the crank until one piston is all the way up, front or rear cylinder. After you get the piston in, carefully rotate the crank until the middle piston is high enough to work into the cylinder. Then, do the last one. It helps if you have someone that can hold the block or rotate the crank for you, but it can be done solo. Don't get upset if it takes 3 or 4 tries. Don't waste your time trying to do it while the engine is in the boat, put it on the bench.

[vwztips]

Genius! Didn't think about hose clamps. Thank you very much for replying.

Currently have the block on my engine hoist as my second set of hands.

[Cranofwaterfell]

I put two pieces of all thread rod about 18" long in diagonal corners of the crankcase to act as guides for the block when trying to lower it onto pistons. It helps some, but still hard to do alone. WAY easier with 4 hands working on it vs two (I've done it alone too).

[steve45]

I put two pieces of all thread rod about 18" long in diagonal corners of the crankcase to act as guides for the block when trying to lower it onto pistons. It helps some, but still hard to do alone. WAY easier with 4 hands working on it vs two (I've done it alone too).

That's a great idea! I've used a similar trick when installing jet pumps and when I replaced the cylinder head on my forklift, but never thought about it for cylinder blocks.

You should copy this to the Shop Tricks section!

[Cranofwaterfell]

Thanks Steve, but I can't really take credit for this idea. The 300 LX manual suggests doing this with two head bolts that have had the bolt head cut off. At 20 bucks a pop for the bolt I figured no way, I'll just go find some all-thread rod to do the same thing.

[FAMT]

i just build an 1100 kawi last year on the bench it is very easy with two people.

i also chagedn psitons while the engine is in the hull, sxr 800 hull so less space to work very hard to install those cylinder to the pistons. i used zip ties around the rind to compress them and then cut them when in the cylinder