Pistons. Swapping heads. Cylinders.
Article 60, sub-section 4
Be sure to read these articles:
DO NOT glass-bead blast the heads, nor cylinders, nor pistons. Hard media will get into everything, & even after very careful cleaning some is left, even into the metal surfaces and eventually these tiny particles may get into all sorts of other areas, like bearings, and upper end areas....where they will cause fast wear. Besides those problems, blasting pistons with glass beads can easily be overdone, can cause WEAR just from the blasting, let alone the residues that did not wash/brush out. DO NOT use such blasting media. Walnut shells can be used. Use of soda or CO2 blasting or straight hi pressure vapor, is OK ...but the soda method requires an exceptionally good cleaning afterwards ...and the stuff gets into everything in the vicinity.
Swapping heads, cylinders, pistons:
MANY questions have arisen on swapping cylinder heads, cylinders & pistons between the various models of Airheads. I am NOT going to discuss every possibility. If your question is not answered HERE, ask on the Airheads LIST.
1. In 1976 BMW changed the crankcase to accommodate 99 mm diameter base cylinders, previously cylinders were 97 mm. Thus later cylinders don't generally fit earlier cases; but EITHER case or cylinder can be machined. Some early 99 mm base cylinders were made without grooves for the large O-ring, all later ones had a very large O-ring, having a machined groove for it on the cylinder base. It is possible to install Nikasil cylinders on some pre-1981 engines. You have to trim a small amount of material at the bottom of the cylinder, inboard of the O-ring groove. You need the cylinder in a lathe to do this. This needs explanation, as there are two styles of Nikasil cylinders. The first versions, used between 1981 and 1984, were the same as the earlier cylinders, that is, they do not have a small step above the O-ring groove, & fit the earlier cases directly with no problems (assuming 1976 or later engine case). LATER than 1984 cylinders do NOT directly fit the pre-1981 cases. You have to machine-off the step so they will fit. YOU COULD USE them WITHOUT THE O-RING, but the O-rings can help with possible oil leaks/weeps. Piston ring rotation; orientation; cylinder crosshatch:
2. You can fit Nikasil cylinders pistons from a R80 into a R75/7. The squish band is different on R80 pistons, but the clearance is OK.
3. 1000 cc cylinders won't fit R90S heads. There is a head gasket difference with the R100 & all the smaller displacement sizes. You COULD use R100 heads and cylinders and pistons.
4. Problems are with the R100 engines with HIGH COMPRESSION pistons. The high compression heads & pistons were on U.S. 77-78-79 models of the R100. See 8., below.
5. It is possible to combine European high compression ratio pistons & heads & Nikasil cylinders.
6. Almost always, using larger displacement on an engine that came with smaller displacement, will result in more vibration ...or power pulse feeling. Beware of trying to fit larger cylinders from the R75/5 into a R60/5 or R50/5, because the CAMSHAFTS are VERY different, and can cause problems, although the camshafts can be changed to the R75/5 type, etc.
7. Do not mess up the piston circlip if you intend to reuse it ....I do not, I replace them every time. When removing or installing circlips, do not do more than just the amount of pressure & prying movement needed. The wrist pin circlips have a sharp side & a rounded side. The rounded side goes INWARDS. Old style pistons with internal pin clips interchange with later external clip types. Airhead pistons up through EARLY 1977 used a thin circular INside wire piston pin clip. The later 1977 & perhaps some very early 1978 had a THICKER version of that clip. The piston pin clip on most if not all 1978 and later had the EXterior type. To remove the inside type of piston pin clips, use a hardened tip sharp tool with an L shaped tip. Insert the L shaped tip into the tiny recess, getting the tool behind the clip; move it towards the center of the grooved hole, so as to remove it. To remove the OUTSIDE type of clip, use a conventional circlip pliers. DO NOT mess up the groove! The SLIGHTEST burr on the groove MUST be fixed, otherwise the pin will not fit smoothly.
8. High compression pistons may have problems with the head. Later pistons had the dome extending to the edge; later 1970's types with the squish band were designed to work with a matching cylinder head, & might have to be machined. This might occur with some modification you are attempting, such as later pistons fitting 1977 heads. The squish pistons used on such as the 1977 R100RS are hard to find. The original 'squish' pistons are no longer available. One can modify the head & cylinder (deck height change, about 0.050") and thereby get your own squish pistons in practical use. The 1977 year was different regarding the pistons. The 1978+ had a different shape for the pistons ...at the edge as an example. The 1977 style pistons are probably no longer available. Perhaps some PRE-emissions 1978 pistons will work, but you would have to order them & look at them. The 1977 R100 pistons were special, only used in that year & model. If you have a 1977 R100 & need pistons, you could consider using the 9.5:1 1978 pistons with the outside circlip.
9. You can NOT trust the latest parts information at the dealerships.
10. SOME pistons were manufactured with the VORN and arrow stamped wrongly ...that is, in the reversed position! Be SURE you have the piston installed in the correct direction!
Piston rings DO rotate. They are designed to rotate; only a few engine types do not have rotating rings. Those non-rotating ring engines are mostly the 2-stroke type with ports on the cylinder walls, that you would not want the ring ends to grab onto or be opposite. There ARE some 4 stroke exceptions. The roundness of the cylinder has an effect, and there are some smaller effects. The cross-hatch pattern that is done by the factory is very specifically designed to cause ring rotation during break-in. When boring or otherwise renewing a cylinder when real honing is being done, the crosshatch has to be done correctly. The proper cross-hatch is done with a specific angle, best done on an automatic machine, and if done correctly it will hold a miniscule amount of oil during break-in, and cause proper ring rotation at that time.
My http://bmwmotorcycletech.info/cylinders.htm article gets into this deeply.
Piston ring rotation; orientation; cylinder crosshatch:
Rings should be set roughly 120 degrees from each other 'IF' you removed the piston assembly from the cylinder. I HIGHLY disagree with those that say it does not matter if the rings are lined up any which way. Rings do move but mostly with fresh crosshatched bores and initial few miles of break-in, then they tend to be stable; however, they can move (rotate) again; and likely will, particularly on the Nikasil cylinders. You should not put the oil ring end gap at the bottom. The reason is an accumulation of oil ...particularly when the bike is on the side-stand.
Genuine BMW rings usually have a top & bottom, with the top marked, sometimes very faintly. Due to wear patterns, besides ring design, ALWAYS return the rings to the same top/bottom orientation. Do not install a ring upside down from a specified orientation in the first place. BMW piston rings are usually marked TOP near the ring gap. Don't assume that pistons, like new ones from a dealer, have the rings on correctly. The older style of oil rings may or may not be marked TOP. Failure to observe the orientation of the ring will result in high oil usage. If put in upside down, very easy to do, your cylinder will burn oil.
The TOP RING, also called the compression ring, means the ring closest to the top of the piston. Use a magnifying glass. The inner portion of the ring has a tapered edge that faces the head (or top of the piston), that is, outwards.
The 2nd ring (ring in middle) has a notched outer edge. The notch faces the engine case. On the 1981+ style 2nd ring, that ring is marked for the top, the bevel does face the crankcase.
Here is the proper orientation of the ring end gaps, based on the common analog clock, as you face that side of the engine:
LEFT SIDE: outer, compression ring: 4:30
2nd ring: 10:30
innermost (oil ring): 1:30
RIGHT SIDE: outer, compression ring: 7:30
2nd ring: 1:30
innermost (oil ring): 10:30
BMW Airhead pistons have a front/rear and you can cause SERIOUS problems if you do not assemble the piston to the rod with the small stamped arrow, located on the top of the piston near the center, pointing forward. There will be the word VORN (German for FRONT) next to the arrow. It may be covered with carbon. If using aftermarket pistons, they may not be marked, and the valve cutouts will usually give you the correct installation, just from inspecting the cutout sizes, the intake being bigger. There have been a few instances where the VORN and indicating arrow have been reversed. DO check your pistons ....the intake cutout is larger.
DO NOT put the pistons that were in your left side, into the right side, & vice-versa. Pistons operate such that one side gets much more pressure (thrust effects) than the other, wear patterns must be maintained, as well as shape.
Most Airheads specifications are for a maximum cylinder ovality of ~0.0004" and a maximum cylinder taper of 0.0008". The piston clearance is typically 0.001" on the smaller bores, to 0.002" for R100 engines. The Nikasil/Galnikal cylinders use a piston clearance of approximately 0.0015".
The factory specified ring end gaps, prior to Nikasil/Galnikal, were top ring at 0.012-0.020". Nikasil/Galnikal use about 0.020" for the top and second ring; and 0.013" approximately for the scraper ring. These values I give here are in brief, the factory manuals give the exact gaps for each ring for all the various models. The information here, however, is OK. What do I do, myself? I don't go by the factory books, nor Haynes, nor Clymers, etc. I fit rings for end gaps that are about 0.0035" per inch of cylinder bore. DO NOT make the mistake of fitting rings with too little end gap!
Note that BMW rings as supplied may have larger end gaps than the manual states; and are OK. I would NOT be inclined to try to install rings with the minimum the factory specifies ...somewhat more end gap is actually preferable on our Airheads. NOTE that one can use oversize rings to fit worn bores on the PRE-Nikasil cylinders and then adjust the ring gap by filing the ring ends. This may not be perfection, but in practical usage it works fine, but do this ONLY on the first oversize (0.25mm). DO NOT do that with the Nikasil/Galnikal cylinders. Rings for Nikasil and Galnikal are NOT made the same way nor are they the same material as for the old steel cylinders! Pistons ARE the same for Nikasil and steel bore cylinders. NOTE AGAIN: The rings are NOT the same material and design.
The information in the following scans from Clymers are for your general information.
There are plenty of styles of rings.
Below is information on Pre-Nikasil piston and rings. The Nikasil rings have a spring expander, and the two bevels are opposed. Photos and text in photos show order of installation:
Here are two additional photos, note the type of ring construction on this particular set of rings. Note carefully the bevels on the oil control ring, and what would happen if the ring was installed upside-down!:
/2 era cylinders are not made the same way as the /5 (through all except the Nikasil/Galnikal and later). The /5 and later, prior to Nikasil/Galnikal, had cast-in steel liners. Compare the ring bevels below, with the two photos just above!
NOTE how the oil ring bevels are different on this type of oil ring, from the Clymers manual sketch type of symmetrical ring.
NOTE that some types of rings use a ring-expander behind the oil ring. Nikasil rings for example.
Oversize pistons from BMW are NOT available for the 1981+ cylinders.
Selected graded pistons to fit the bore are available. AFTERMARKET pistons ARE available.
The following information on AFTERMARKET pistons is believed accurate, but has not been checked in great detail by me: San Jose BMW (CC products) sold some pistons for a 1050 cc kit that gives 1038 cc. These pistons were forged types, by Venolia. The diameter was 3.810" (96.774 mm). Alloy 2618, a low silicon, was used. This means these pistons expand at a goodly rate when they get hot, so MORE piston clearance is needed. Try 0.0035" minimum. Alloy 4032 would wear better, and expand less, but 2618 is stronger. If a crack occurs in 2618, the crack may well find an area of lower stress and stop ...not so the 4032. So, 2618 is a GOOD choice for piston material, and holds its shape better under high stress use too.
If you are going to use aftermarket pistons, ASK about proper clearance specifications. This is a good idea for ring gaps too.
NOTE: Various 'books' (including BMW's own literature) have somewhat conflicting information on ring end-gaps. It is also MY belief that most of BMW's literature has the minimum specification for end gaps TOO SMALL. I prefer somewhat wider end-gaps. I usually use around .5-.6 mm for all three rings. Whether or not to change rings on an engine that is apart, yet is not an oil burner, is a good question. This is particularly so on the Nikasil cylinders. I would let them go until quite wide and actually showing signs of real oil burning. I mention my method of gap per inch of piston size, well above.
Mahle makes a big bore kit using 97 mm pistons, giving 1043 cc.
Pistons are purposely tapered to be bigger at the skirt end, so be careful when measuring things.
See the following websites:
You can also check with German websites, etc. ....pistons/cylinders/rings are available from Europe that are not available in the USA.
PISTONS AND RINGS ARE TO BE INSTALLED "LIGHTLY" OILED ...not dry. Lightly means the faintest amount of oil that can be used as an oily film, it does NOT mean squirting with an oil can! A few drops, ON YOUR FINGERS/HANDS, then spread with those fingers. Perhaps a FAINTLY oily rag on the cylinder walls. I use a straight mineral oil, not a multigrade.
If a groove that the piston rings fits into is heavily worn, the ring will rock with respect to the piston far more than needed, and things can get bad enough to break rings and pistons. Pistons DO wear out.
You do NOT need an expensive tool to measure cylinder taper. You might not even bother to measure the taper on a Nikasil cylinder. For the earlier cylinders or Nikasil cylinders, why not do it ...and do it easily! Install a piston ring, squarely to the bore (use a piston, if you need to, to get square orientation), it need not be an original ring off your piston, just one that fits. Use your feeler gauge set to measure the ring end gap, and do this at a point just inboard a bit from the top of the cylinder ridge wear area. Write down the feeler gauge thickness. Redo the measurement near the bottom. For each measurement, divide by pi. Compare them. Simple, wasn't it!
Piston clearances generally, unless there is real damage, don't go much over a few thousandths ...certainly not the 4.5 specification limit. It is perfectly OK to use next oversize rings, adjusting the end gaps, when you have a bike with a good bore. If you do this, we shall assume the bore has low taper, but the rings are perhaps on the edge of high specifications or bit over. You can purchase an oversize set of rings and adjust the end gaps to specifications, but when doing this, use the smallest measured part of the bore ...usually near bottom, where the diameter of the bore in the lowest area that the rings normally contact, is the smallest ...adjust the new oversize ring gaps for that diameter. I don't bother replacing rings if the end gaps are just a bit larger than maximum specifications.
Cylinder base shim/gasket/compression plates: see http://bmwmotorcycletech.info/cylinders.htm that treats this in depth.
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Last check/edit: Wednesday, October 05, 2016