9

SECTION 9
Pistons – Rings – Rods
Section Contents
Page
PISTONS
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check Piston Ring Land Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install in Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PISTON PINS
Piston Pin Reject Sizes, Table No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RINGS
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check Piston Ring End Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ring End Gap Reject Size, Table No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONNECTING RODS
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Connecting Rod Reject Size, Table No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Connecting Rod Screw Torque, Table No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install in Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

NOTE: SPECIFICATION TABLES BEGIN ON PAGE 8 OF THIS SECTION.

1
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Remove Piston and Connecting Rod

1. Bend down rod bolt lock (1), when used, Fig. 1. 1
2

Connecting rods without rod bolt locks use one or

two thin washers, or washer-head bolts. On con-
necting rods with dippers held by both connecting
rod bolts, no washers or rod bolt locks are used.
2. Remove connecting rod cap (2).
3. Remove any carbon or ridge at top of cylinder bore
to prevent ring breakage on cast iron sleeves or
cast iron cylinders. The ridge does not have to be
removed on aluminum cylinder bores. Fig. 1
4. Push piston and rod out through top of cylinder.

NOTE: All pistons have oil drain slots or drilled

holes in the oil control ring groove except
for Model Series 120000 pistons, which
use drain slots in the ring lands.

NOTE: Pistons used in CAST IRON SLEEVE

BORE aluminum alloy engines CANNOT
BE USED in Kool Bore¥ (aluminum bore)
engines. Pistons used in Kool Bore¥ (alu-
minum bore) engines are chrome plated.
These chrome plated pistons CANNOT
BE USED in SLEEVE BORE engines.
5. Use “Illustrated Parts Lists” to determine which
pistons to use based on Model, Type and Code.
Remove Connecting Rod
All Model Series Except Current Model 3
1
Series 170000, 190000, 220000, 250000,
280000
Some pistons use a piston pin with one end flat and the
other end recessed. All other pistons use a hollow
piston pin. Some pistons use two piston pin locks while
other pistons use one piston pin lock and a piston pin
stop in the piston.
4
1. Remove a piston pin lock (1) with needle nose 2

pliers (2). One end of the pin (3) is recessed (4) to

facilitate removal of the lock, Fig. 2.
Fig. 2
2. Push piston pin out from other side.
Current Model Series 170000, 190000,
220000, 250000, 280000
1. Rotate piston pin retainer (5) until one end is
exposed in notch in piston pin bore (6), Fig. 3.
2. Grasp end of piston pin retainer with needle nose
pliers, pull in and up to remove retainer.
6
3. Push piston pin out from other side.
5

Fig. 3

NOTE: SPECIFICATION TABLES BEGIN ON PAGE 8 OF THIS SECTION.

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Remove Piston Rings

Remove piston rings using Piston Ring Expander Tool,
#19340, Fig. 4.

NOTE: Some oil control rings consist of two thin

steel rails and a spring expander. These
steel rails cannot be removed with Piston
Ring Expander, Tool #19340. Grasp one
end of the steel rail and wind the rail from
the oil ring groove into the next ring groove.
Repeat as necessary to remove from
piston.
Fig. 4
Check Piston
If cylinder is to be resized, a new oversized piston
assembly will be used.
If cylinder will not be resized, inspect piston for signs of
wear or scoring. If condition is acceptable, check ring
land wear.
Check Piston Ring Land Wear
1
1. Clean carbon from top ring groove.
2. Place a NEW ring in the groove and measure the
Fig. 5
space between the ring and the ring land (1). If a
.007” (.18 mm) thick feeler gauge, Model Series
60000 through 130000, or .009” (.23 mm) thick
feeler gauge, Model Series 170000 through 3
320000, can be inserted, the piston is worn and
should be replaced, Fig. 5. 2

Check Piston Ring End Gaps

1. Clean all carbon from the ends of the old piston 4

ÇÇ
rings (2) and from the cylinder bore.
2. Insert rings one at a time 1” (25.4 mm) down into
the cylinder.
3. Check gap with feeler gauge (3), Fig. 6. If ring gap
ÇÇ Fig. 6
(4) is greater than shown in Table No. 1, Page 8,
the ring should be rejected.
Connecting Rod and Piston Pin
Rejection sizes of crankpin bearing hole and piston pin
bearing hole are shown in Table No. 2, Page 8. If the
piston pin is worn .0005” (.01 mm) out of round or
below the rejection sizes listed in Table No. 3, Page 8,
it should be replaced. Piston pins .005” (.13 mm)
oversize are available in case the connecting rod and
piston are worn at the piston pin bearing. If the crankpin
bearing in the rod is scored or worn, the rod must be
replaced. Do not attempt to “file” or “fit” the rod.
Assemble Piston, Pin and Connecting Rod
Piston pins are slip-fit in the piston and connecting rod.
Some pistons use a piston pin with one end flat and the
other end drilled. All other pistons use a hollow piston
pin. Some pistons use two piston pin locks while other
pistons use one piston pin lock and a piston pin stop in
the piston.

NOTE: SPECIFICATION TABLES BEGIN ON PAGE 8 OF THIS SECTION.

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Piston Without Notch on Head

1. Install one pin lock in piston pin bore groove. (If 1
bore is grooved for two locks.)
2. Place rod inside piston and slide piston pin into
piston from side opposite lock or piston pin stop
then through piston and rod until pin seats on lock
or stop. Install (remaining) pin lock.
Piston With Notch on Head
The notch on the piston faces the magneto side of the
engine.
Fig. 7
1. On pistons except Model Series 300000, 320000,
install one pin lock in bore groove opposite notch
(1). Place rod in piston with offset rod cap to left 1
4
side of piston, Fig. 7. Push piston pin from notch
side of piston through piston and rod until pin seats 2
5
on lock. Install second piston pin lock, (when
used).
6
2. Model Series 300000, 320000 have a notch (1)
and letter “F” on the piston. Install pin lock (2) in pin
bore groove opposite the notch and letter “F.”
Place rod in piston with assembly marks (3) on
same side as notch and letter “F”. Install pin
through piston and rod until pin seats on lock.
Install second lock, Fig. 8.
3

NOTE: The top ring (4) and center ring (6) are the
same. Both rings use marks (5) to identify Fig. 8
the top of the rings.
Install Piston Rings
Install the oil control ring first, then the center
compression ring. Install the top compression ring last,
as shown in Fig. 9 and Fig. 10. Use Piston Ring
Expander, Tool #19340. Install expander under oil
control ring, when equipped. Typical piston ring cross
section for aluminum bore engines, Fig. 9.

Fig. 9

NOTE: SPECIFICATION TABLES BEGIN ON PAGE 8 OF THIS SECTION.

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Typical piston ring cross section for cast iron sleeve

and cast iron bore engines, Fig. 10.

NOTE: Some compression rings have an iden-

tifying dot on the top of the ring. Always
install ring(s) with dot facing top of piston.

NOTE: On oil rings that use two thin steel rails and
spring expander, install expander first.
Twist one steel rail at a time down from one
ring groove to the next and onto the
expander.

Fig. 10
Install Piston and Rod Assembly in Cylinder
1

NOTE: See section 11 for additional information

regarding rings, cylinder honing and/or 2
resizing prior to reassembly.

Fit Ring Compressor to Piston Assembly 3

1. Oil piston rings and piston skirt.
Illust. 1 Illust. 2
NOTE: On aluminum bore engines, use ring
Fig. 11
compressor with the projections (2) at the
top (1), as shown, Fig. 11, Illust. 2.
On cast iron sleeve and cast iron cylinder
engines, use ring compressor with the
projections (2) at the bottom (3), as shown, 4
Fig. 11, Illust. 1.

5
2. Insert the piston assembly (5) into the piston ring
compressor (4), Fig. 12. Use Ring Compressor,
Tool #19070 (Model Series 60000 through
130000), or Ring Compressor Tool #19230 (Model
Series 170000 and up).
Fig. 12

NOTE: SPECIFICATION TABLES BEGIN ON PAGE 8 OF THIS SECTION.

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3. Place piston assembly (5) and compressor upside 7

down on bench and push piston down until head of
8
piston is even with edge of compressor (6),
Fig. 13. 5

4. Tighten compressor with wrench (7) until piston

cannot be turned in compressor.
5. Then loosen compressor until piston can be turned
with slight resistance.
Do not attempt to install piston and ring assembly
without ring compressor.
6

Install Piston Assembly

(Without Notch On Head) Fig. 13
1. Place connecting rod and piston assembly with A
compressed rings into cylinder bore (8), Fig. 13. 9

2. Position rod so correct side is facing cam gear (A).

Turn crankshaft until crankpin is at top dead
center.
(With Notch On Head)
1. Place rod and piston assembly with compressed
rings into cylinder bore with notch on piston facing 10

magneto side of engine. 11

2. Turn crankshaft until crankpin is at top dead

center. Fig. 14

(Remaining Steps For Both Types)

3. Push piston down by hand until rod rests on A A
crankpin.
9
10
4. Oil crankpin and install rod cap with match marks
(9) or flats (12) aligned, Fig. 14.
5. Place shop rag over piston and ring compressor to
protect hands.
6. Assemble connecting rod bolt, rod bolt lock (10, 9
when used), and dipper (11, when used). 10

Typical styles of locks and dippers are shown in 11 11

Figures 14 – 18.
Fig. 14, Aluminum Model Series 60000 Fig. 15 Fig. 16

Fig. 15, Aluminum Model Series 80000, 111000,

112000, 120000, 190000, 220000, 250000 A A
12
Fig. 16, Aluminum Model Series 100200, 130000, 12
170000
Fig. 17, Early Cast Iron Model Series 230000 9

Fig. 18, Cast Iron Model Series 230000, 240000,

9
300000, 320000
10
10

11

Fig. 17 Fig. 18

NOTE: SPECIFICATION TABLES BEGIN ON PAGE 8 OF THIS SECTION.

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7. Torque bolts with Torque Wrench, Tool #19197 or

19393, to specifications listed in Table No. 4, B
Page 8.

NOTE: Some Model Series 280000 engine

connecting rods using two different size
connecting rod bolts.
A

A. FIRST torque 3/8” hex connecting rod screw to

160 in. lbs. (18 Nm).
B. NEXT torque 1/2” hex connecting rod screw to Fig. 19
260 in. lbs. (23 Nm), Fig. 19.
8. Rotate crankshaft at least two complete
revolutions to be sure connecting rod and
10
crankshaft turn freely and connecting rod does not
interfere with cylinder or cam gear.

NOTE: If connecting rod interferes with cylinder or

cam gear, rod is installed incorrectly or
ÁÁÁ
ÁÁÁ
cam gear is out of time. Verify correct
timing and connecting rod installation 9

before proceeding.

13
9. If rod and crankshaft are free, bend rod lock (10, 10

when used) against flats on screw heads (13),

Fig. 20. Fig. 20

NOTE: Some service rods are shipped with two

thick washers under bolt heads. Remove
and discard these washers. Use two thin
washers when no dipper is used. Use one
thin washer under bolt not holding dipper.
No washers are required when dipper is
held by both bolts or equipped with washer
head bolt.

NOTE: SPECIFICATION TABLES BEGIN ON PAGE 8 OF THIS SECTION.

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SPECIFICATION TABLES
TABLE NO. 1 TABLE NO. 3
Ring End Gap Reject Size Piston Pin Reject Sizes
Compres- Basic Model Piston Pin Pin
Oil
sion Series O.D. Bore I.D.
Ring
Rings
Inches Inches Inches
Inches Aluminum Cylinder
(mm) (mm) (mm)
(mm)
Aluminum .035 .045 60000, 80000,
Cylinder Bores (.89) (1.14) 90000,100700,
110000, 120000 with .489 .491
Cast Iron .030 .035 small pin before (12.42) (12.47)
Cylinder Bores (.76) (.89) Date Code
970113XX
TABLE NO. 2
Connecting Rod Reject Size 120000 with large
.6242 .6265
pin after Date Code
(15.855) (15.913)
Basic Model Crank Pin Piston Pin 970112XX
Series Bearing Bearing 100200, 100900 .552 .554
Inches Inches (14.02) (14.07)
Aluminum Cylinder
(mm) (mm) 130000 .489 .491
60000 .876 .492 (12.42) (12.47)
(22.25) (12.50) 170000, 190000 .671 .673
(17.04) (17.09)
80000 1.001 .492
(25.43) (12.50) 220000, 250000, .799 .801
90000, 100700, 280000 (20.29) (20.35)
110000, 120000 Cast Iron Cylinder
1.001 .492
with small crankpin
(25.43) (12.50)
before Date Code 230000 .734 .736
970113XX (18.64) (18.69)
120000 with large 240000 .671 .673
1.097 .6271
crankpin after Date (17.04) (17.09)
(27.86) (15.928)
Code 900112XX
300000, 320000 .799 .801
100200, 100900 1.001 .555 (20.29) (20.35)
(25.43) (14.10)
130000 1.001 .492
TABLE NO. 4
(25.43) (12.50) Connecting Rod Screw Torque

170000 1.095 .674 Basic Model Series Torque

(27.81) (17.12) Aluminum Cylinder in. lbs. (Nm)
190000 1.127 .674 60000, 80000, 90000, 100000, 100
(28.63) (17.12) 110000, 120000, 130000 (11)
220000, 250000, 1.252 .802 170000 165 (19)
280000 (31.80) (20.37)
190000, 220000, 250000 185 (21)
Cast Iron Cylinder
280000 Both Screws Same Size 185 (21)
230000 1.189 .736
160, Small
(30.20) (18.69)
(18) Small
280000, Two Sizes of Screws
240000 1.314 .674 260, Large
(33.38) (17.12) (23) Large

300000, 320000 1.314 .802 Cast Iron Cylinder

(33.38) (20.37) 230000, 240000, 300000, 320000 190 (22)

NOTE: SPECIFICATION TABLES BEGIN ON PAGE 8 OF THIS SECTION.

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