Any tips on installing piston Circlips?

[Turbota]

I haven't got my pistons and cylinders back from NRHS yet, but I was practicing installing my old Circlips on an old piston. These things are a real pain! Best tool I found was just a pair of larger needle-nose pliers, but not great.

NRHS said they would send me the pistons already in the cylinders bores so I can pull them out just far enough from the bottom of the cylinder bores in order to install them on the connecting rods (I don't want to pop the rings out of the bores if I don't have to).

Anyway ... Trying to install these Circlips, it's not easy ... It IS easy to ding up the side of the piston while trying to install them with needle-nose pliers.

Any good tips?

Thanks,
Ron

[RedRider]

Ron, I have never dealt with these on motorcycle engines, but used to put them on performance V8's frequently. These are probably the same style. I used to use a small flat-tip screwdriver to push them into the wrist pin bore until they seat in the groove. Otherwise, I just use my fingers to work them in. You are right about having to be careful about not damaging the piston if you decide to use something else. Hope this helps some.

[Turbota]

Thanks Red Rider. I didn't try a small screwdriver. I did try useing my fingers, but the Circlips are just too stiff.

Nice to see another Gulf war vet. I too was there in 91. Was an activated Reservist. Flew out of KKMC in Saudi and the Kuwait Airport.

Ron,

[RedRider]

Nice to see another Gulf war vet. I too was there in 91. Was an activated Reservist. Flew out of KKMC in Saudi and the Kuwait Airport.

Ron,

Cool, Ron. I was with the 1st Marine Division (Task Force Shepard) when we made the push through southern Kuwait to capture the International Airport. I'm sure we could swap a lot of stories....

Good luck with your motor.

[Gyahmers]

I use a small pair of flat tipped needle nose pliers. The nose of the pliers has a flat face about a 1/4" long. Grab the ring at the bottom of the circle with the ends pointing up. Position the ends of the ring (The ends are still pointing up.) into the groove of the piston as a starting point. Get a good grip on the pliers and push up and in. A couple of attempts and you'll have it down like a pro. Takes only a couple of seconds.

[HrdlyDangrs]

Harley makes a tool just for that...its part number HD-34623A which is suppose to make the process less painful....course I can't say it will do the same for your wallet....**Check with your local HD Shop and get a price and availability for this tool....may be worth it.

**This part #HD-34623A is good for early 90's Evo pistons....your bike may require a different number.

****USE NEW CLIPS****DO NOT RE-USE YOUR OLD CLIP!!!

After installing make sure the clip moves around in its groove to ensure complete seating of the pin.....I believe that the gap in the ring should face up once inserted.

Wear a set of safety glass when doing this procedure...the clip has a tendancie to fly out when removing and can slip and fly out when installing.......SAFETY FIRST!!

[TechRep]

Here’s what worked for me…

I played with my clips for awhile trying to figure out the easiest way without damage.… I ended up starting one end, and kind of rolling it most of the way... then used a small old brass punch I had (I put a small "V" on the end) to push in the last bit, and they popped in. It was way easier then getting mine out!!
I put one clip in each piston so I could slide the pin in all the way to the clip when I lined up the rod and lowered the Jug/piston assembly. Then I popped in the other clip. The rings fit pretty snug, so having the rings pull out was not an issue.

Hrdly is right about the clips flying.... When I was taking mine out one of them "pinged" right past my right eye at about Mach 3. Never found it. Safety glasses were on, but....

[flathead45]

stainless steel forceps, good german ones not the cheap pakastan ones

[IronMick]

Hey guys,

Any tool shop or auto supply store has Circlip Pliers. You can buy a kit that has attachments for the various styles of circlip: inside, outside, etc. These work far better than any home-spun tool. Always, the right tool for the job!

[Turbota]

Thanks for all in input

IronMick ... I am familiar with the inside and outside tools that are used to install regular "C-Clips". I guess they are actually "Snap Rings". Those clips have a small hole in each end so the needle points in the C Clip ring pliers can insert into the holes and expand them ....

http://www.tecratools.com/pages/service/graphics/12129l.gif

http://www.arconring.com/Imgs/home.jpg

But the Circlips in these Harleys are just a piece of spring steel wire that have no holes in the ends to install one of those C Clip ring pliers ....

That's why I am confused as to what type of tool to use to install them.

[rottenralph]

I did mine with no problems. Just make sure you cover up the hole in the case. I dropped one in the first time I had my bike apart and it took two hours of fishing with a magnet before i got it out. They should go in easy on new clean pistons.

[HrdlyDangrs]

On my old 68XLCH I had picked up a set of Nylon 'buttons' that took the place of the circlips. They were available for awhile...I can't remember who manufactured them....I wonder if anyone makes these nylon buttons for the Evo motors??

I looked for them when I built my current 74XLCH a couple seasons ago...but didn't find them....Don't know if I gave up looking for them cause I didn't find them right away or just went with the circlips when I go to that point of engine building.

Anybody know what I'm talking about or have seen these nylon buttons????

[gamhill]

Make sure you leave the tappets in their bores, when your putting the clips in. A better idea would be to this side first, and slip the pin in from the other side. Try and keep any open areas covered - this will help prevent a clip from dropping inside the engine.

Take your time, make sure the clip is snapped into piston, you might want to take a small flat head screwdriver to ensure the clip is snapped in.

[Turbota]

Thanks everyone :)

If you look at the picture I posted ... Those are Snap-Rings. Very easy to install with those Snap-Ring pliers.

I wonder why H-D don't use regular Snap-Rings instead of these Circlips that don't have the holes to use a tool in to compress them?

I would bet that you could just install Snap-Rings instead ... Of course, you would need to find some that fit perfectly.

[stevo]

OK a few things here guys..........

SAFETY GLASSES

As mentioned there is a specific tool... never used it but I'm told it's the ducks guts...

I use a pointy nose pair of pliers....

I push one end of the clip in and then grab the clip and sorta roll /push it into the groove..

I position the ring so the pliers will go into the small relief hole as they are used to push the circlip in...



Just to add to the crap that was put forward the other day by some idiots that thought they knew more than they obviousy do......

Most V8 stuff uses a shrink fit on the pin to hold it in the conrod.... that's why guys with a V8 background will often have not seen this type of pin retainer before..


The teflon or nylon button idea can be used in certain instances but it has some problems too that we aren't going to get into here..


DO NOT RE-USE CIRCLIPS ..... they are a single use only item....... if you think you have stressed the clip too much getting it in.. then take it out and get another one...

I've never had a motor drop a circlip BUT I've repaired quite a few that have..

[HrdlyDangrs]

Be careful who you refer to as an idiot....some of us are very sensitive.. :geek