The Hodaka Club Forum

Most times you can just put a piston and rings in a cylinder and get away with it, and that's how most folks do it. But occasionally things will be a little tight, and I found it's easier to check it and adjust as necessary as it's being assembled than to have to tear it all down again after a seizure or worse. You'll get it done. It looks like everything will fit. Your wood block will be a huge help. I'm always impressed by all you get done usually in a very short period of time. Good luck and Happy Thanksgiving!

The "tuning fork" block is a virtual necessity. It keeps the piston standing up straight while you handle ALL of the following items at the SAME TIME.
Note that I am not going to number the items because that suggests some sort of priority - and that would be false - ALL these factors have to be right at the same time
.
- top ring end gap properly centered at anti-rotation pin
- piston standing straight on the "tuning fork" block
- piston ring compressed as fully into its groove as your one hand can manage so the chamfer in the bottom of the spigot can take over the job of the compressing the ring into the groove (keeping the end gap centered over the anti-rotation pin)
- cylinder in other hand is then guided down to "swallow" the piston and compressed ring while also fitting over the studs

There, you've got 'er done on the top ring . . . now, without losing control of the piston or cylinder . . .

- repeat the above steps while focusing on the bottom ring

It IS a good test of dexterity, but quite doable IF you have the "tuning fork" block to aid the piston alignment.

NOTE: I spent about 20 minutes one time trying to install the cylinder over a single ring piston without the "tuning fork" block because the block was hiding from me. After the 20 minutes of frustration, I called a time out and spent about 10 minutes to search out the hidden "tuning fork" block . . . and installed the cylinder in less than a minute with the assistance of the "tuning fork" block. When I slowed down (and did things right), it went faster.

Ed
PS: Have I mentioned lately, slow down - you'll go faster?

Vic I would use a little light oil on the rings. I also would recommend to go the standard way and start with the piston on the rod,clips in place. I have never used a tuning fork but it sounds like a good thing. One hand on the piston compressing the ring the other guiding the cylinder.---Clarence

The "tuning fork" idea sounds good-- installing the cylinder over the piston was quite a juggling feat. I can visualize what it should look like, but it might be easier if there was a photo of a tuning fork. I couldn't find one.

I'll try to get it on for you. I've never used blocks or tuning forks on the zillion that I've done. Of course it's imperative that the rings are on their pins and a test fit with the piston assembly to insure things are going to actually go in there together. Assemble the piston to the rod and align the rings to their pins using a marking pin for reference. Oil everything as Clarence said. The bevel on the inside bottom of the cylinder is going to be your ring compressor. Start the cylinder down on the studs while holding the piston vertically. Slightly rock the piston bottom and feed it into the bevel. Don't force anything but only rock the piston and cylinder so the ring will be pushed into the groove. You can practice this on the bench with the cylinder upside down. A bit more tricky with two rings but it always goes on with the proper clearances. See if any of this helps as this has never been a major problem for me.

Max

OK. Thanks everyone for all the thoughts & suggestions. I do have the proper small value guage so I can check the measurements.

I can say it was a relief to see the piston with rings on to drop into the cylinder. At least now I know I can get it in there.

Ed, if I go any slower, based on the current rate of activity, it should only take 2-3 weeks to get the piston in the cylinder and a couple more years to get the head on. ; D Victor

Are your ports properly chamfered?

Yup! ; D Victor

i have used 2 pencils or 2 Popsicle sticks before and it worked just fine ..just lay one across each side against the inside of the studs and rotate the crank until the piston is firmly supported

bob

That's clever! Thanks! ; D Victor

Waiting for circlips then I can move forward with the motor. I thought I had a set here but I couldn't find any.... Victor

I order a couple of extra wire clips and stash them in a "small parts box". It's too easy to have 'em sproing and disappear.

YES!! The pencil/dowel/popsickle stick idea is great. Be sure you cover up that open hole-- things love to scurry in.

Yes Bill, for sure! Don't want to have to split the cases for something like that! ; D Victor

Well my circlips came in. It's 26* in the garage and no heater there. Looks like it's going to take a warmer day before I get out there and put this top end together. At least I have all the parts now! Merry Christmas to all the folks out there in Hodaka Land!!! ; D Victor

And it's Winter so you won't be riding til Spring. Beemer needs an alternator part installed, I'll wait til the next warm snap, and also take the wheels in to get new tires.

And it's the Holiday season. Have a Merry Christmas!!

Merry Christmas to you too Bill!!! ; D Victor

My son in law is good at mounting tires by hand, without a tire machine! At least on the Hodska wheels! ; D Victor

A old friend told me you have a old red Arnold Palmer golf bag leaning against the shelves do you want to trade for some Hodaka parts--------Clarence

Clarence. What are you offering? Yes I still have it! It holds a 26 year old set of left handed Spaulding clubs as well! I need a full set of genuine Hodaka turn signal assemblies! ; D Victor

You mean this one, right? ; D Victor

Got my circlips in the mail and installed them. Ran out of time and have to wait till tomorrow to push the cylinder on. Wish me luck! ; D Victor

Hey Clarence. What parts do you want to offer me for the Arnie bag? Let me know! ; Victor

A Yah Hoo is in order!!! It's cold but I got it on! It was cold in the garage so things fit more snugly, but a little more two stroke oil should make it move more smoothly. And the trick with using the pencils as the Tuning Fork worked like a charm! ; D Victor

I was reading this subject and not having done one of these in 50 years but I think a rubber band keeping the pencils from spreading might be a helpful addition to your tuning fork idea. This reminds me of installing the barrels on to the pistons in the VW stroker engine I built a couple months ago.
Just my 2 cents worth.
Doug

Actually the pencils fit quite snugly under the piston & on top of the cases. I actually had to turn the fly wheel a bit to loosen the tension against the pencils to pull them out. But, it was an easy trick & I didn't have to mess up my regular Tuning Fork I use for piano tuning! ; D Victor