First, if I'm in the wrong place in this forum, sorry, it's an old bike, but 4 cyl so I would expect similarities given the problem I'm having.

I pulled the cyl head and cyl on this 4 cyl bike, replacing the rings and valve seals to resolve oil usage problem. Bike is 30yrs old with 25k miles on it. My problem is how to get the cyl back on over the 4 pistons. The cyl sleeve is beveled, so I expected the rings to compress while installing the cyl, but doing 4 cyls at the same time proved ridiculous. So, first attempt, cracked a new ring, crap, there goes $40. For my second attempt, I used hose clamps to compress the rings, expecting the cyl to easily slide over the pistons. Even going gently, I managed to crack 2 rings (this is the second ring down, the thickest most brittle ring).

Unfortunately, the Haynes book is severely lacking in technical instruction and Clymer, my preferred tech book, does not make one for this year/model. The Suzuki technical manual doesn't outline the steps to get the cyl installed either.

For my third attempt, I'm considering removing the pistons and installing them in the cyls on the workbench, then get the whole assemble in place, line up the push rods and push the wrist pins in and install the circle clips. Won't be easy and a circle clip into the crankcase will ruin my day.

Anyone out there work on a 4 cyl have some advise after you stop laughing about my pathetic attempts? My guess is Suzuki probably makes a special tool for this. Thanks.

 

instead of hose clamps, try an inexpensive ring compressor. one piston at a time. Lisle 21700 - Ring Compressor | O'Reilly Auto Parts