WSM Circlip installation

[WhiskeyD]

I'm finally getting around to rebuilding the 717 and I cannot for the life of me get the circlips installed. I've broken both thumb nails and tried working it in with a flat head with no luck. I searched around and people said to put the open end first at 6oclock and work your way up the sides and it will snap into place. Well I cant even get the open end into the groove. Before getting mad and giving up I did manage to barely get the open end into the groove once but the clip popped back out before fully going into the groove and now its very slightly an oval shape compared to the others. The clips are rigid and larger than the groove (of course since they compress). They are the ones that came with the WSM kit so I know they are the right ones. I bought some circlip pliers but they are worthless on these clips since they dont have holes at the opening. Any tips on installing these? I've installed circlips in the past but damn they were no where near as hard as these... and I didn't have a broken finger at the time :cuss:

 

[Dr Honda]

if you've oval'ed one of them... get a new one. You don't want it popping out when the engine is running.

Some clips are a bastard to get in, and there is a special tool to install/compress them... but it's expensive for the job it does.

When I do wrist pin clips by hand... I put one tip in... and roll around it. That will normally get it to drop into the opening. Then... slide it down with a small screwdriver, and make sure 100%, that it's in the groove.

You can try a little 2stroke oil on the piston... but that may make it harder to put pressure on the clip.

 

[mikidymac]

I install one end with the open end facing the bottom of the piston and hold the top of the clip as tight as I can at the top with my thumb. Then with the little groove in the piston I insert a small screwdriver or pick and use that to pry the other open end of the clip into the groove. It gives you a spot to get some leverage under the clip without scratching the clip groove or piston pin bore. Just make sure that when the clip is seated and installed the end gap is not in the cast groove that I was refering to, it is the dimple provided for removing the clip I am talking about not the circular groove the clip actully seats in.

 

[Linescreamer]

I can't see the grove but it sure sounds like it got buggered up. Do a close inspection of the grove and make sure there are NO nicks or rough edges that will prevent the clip from going in. Like Doc said use a new clip if the old one doesn't look 100%. Yes, the clip dia. must be smaller then the grove to seat properly.

 

[WhiskeyD]

Thanks for the tips. I did see the circlip installer tool online but it was a little pricey for building only one engine. I'm going to try again tomorrow afternoon with the other set of circlips I haven't opened yet. If I cant get them this time I'll prolly see if I can find someone locally to install them for me.

 

[Dr Honda]

OK... I just did 6 pistons today, and I paid attention to how I do it. I push the clip into the opening, straight in, with the clip opening up. This will allow the clip to compress, and drop into the hole. Then... use a fat screwdriver to push the open end in.

 

[WhiskeyD]

OK... I just did 6 pistons today, and I paid attention to how I do it. I push the clip into the opening, straight in, with the clip opening up. This will allow the clip to compress, and drop into the hole. Then... use a fat screwdriver to push the open end in.

I'll try that, definitely makes sense. I cant wait to have two skis again. Thanks a lot!

 

[WhiskeyD]

Doc you made it sound so easy that I hopped out of bed to give it a shot on the unopened piston and circlips. I still cant even get the bottom (round part) into the groove. So, I took a few photos to show you what I'm dealing with. The first picture shows me trying to use your method you described. You can see how much the clip will have to compress in order to fit. It just too wide to push in. The second pic shows how it looks with just one end in the groove. The pic makes it look like you can work your way down and back up, forcing the clip into the groove but it just does not want to go. It starts to scratch and dig to the point im afraid im going to score/damage the piston with nothing but the tip in the groove. It doesn't even start to seat into the groove at all. Pics 3 and 4 show the overall size of the clip to the piston groove. The circlips definitely look like they will fit but its a matter of compressing them without damaging them and/or the piston. Does this look normal and I just dont know what I'm doing or what? I've always been able to figure out my sea doo problems but this is one I just cant get to work!

 

[WhiskeyD]

Are the pics visible?

 

[Dr Honda]

Yep... I can see them.

 

[Dr Honda]

OK... I had the old pistons down in the garage. These are Merc pistons... but it's the same thing.


Size is good. Not bent.

Push the rear of the clip into the hole with your finger.

Push the open end in with a big screwdriver. (you may have to hold the rear of the clip)

This took more time to type than to install the actual clip.

 

[bigJake]

great learning thread for those of us that have never had the opportunity to replace a piston. stupid question - Doc made installaion look so easy, is the hole just right of the 12:00 position in Docs last pic there to give you a place to grab the clip to remove it? Just pry it out with a screwdriver or special tool?

 

[Dr Honda]

You can generally roll the clip in the groove with a small screwdriver to position it. (so you can get a pick in the opening, and lift the clip out)

 

[WhiskeyD]

Thank you for taking the time to help me Doc. Those clips you posted look a lot easier to install than mine! I ended up just taking it to a shop wayy across the city since I couldnt get them in. It took the tech a minute to get one installed too, so that made me feel a little better haha. I did oval one like I thought so he couldn't finish but he told me to just bring it back when the new ones arrive and he will do it for me. He said these WSM clips were pretty thick and thats why they are so difficult to install. He installed one end on each piston by pushing the clips perpendicular to the piston to compress them and then rotating them into place. That wont work once the wrist pin is installed though so I'm curious to see how hes going to compress the circlips enough to get them in position to be pushed in with a flat head. Hopefully everything will go smooth and I can get this thing built and installed next week!