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Changing pistons
- Changing pistons in AC
started by Killa580EFI
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October 21st 2009 at 6:34 PM
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Killa580EFI
Starting Member
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15 Posts
Group: Members
Member Since: October 14th 2009
Location: S.C., Sask, Canada
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How hard is it to change the pistons in a 1997 AC ZR 580 EFI and what eles do I have to do/change/check?
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October 21st 2009 at 6:57 PM
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Blackcat
Senior Member
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3715 Posts 
Group: Members
Member Since: October 24th 2004
Location: Stanley, ND, USA
Current Sled: 94 AC ZR580
2008-2009 Miles: Notta
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Pretty easy actually. You'll need all associated gaskets to take off the jugs, base gasket, head gasket and water manifold gaskets if you need them...not sure on the '97's...so on and so forth.
Most important thing to check is the clearance between the rings once it's installed in the jugs. The instructions will give you a spec, make sure you check it with a feeler gauge and file if need be to get them within specifications.
Get your jugs honed/deglazed when they are out so the rings can seat in properly. Some may say you don't need to, but it definitely don't hurt anything and it's better then having to tear everything down again because they didn't seat.
'94 ZR580
Remember, the things we say and write not only effect those it was intended for, but can also effect the greater population...whether good or bad.
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06-07 Sleddin' Season Stats
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October 21st 2009 at 7:39 PM
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stormrider62033
wally
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4729 Posts
Group: Members
Member Since: December 25th 2004
Location: Gillespie, IL, USA
Current Sled: 99xcr 800
2008-2009 Miles: 500
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those are coated bores make sure there ok ,if not need them recoated or sleeved
mid Il alway's waiting for snow,moving north(way north)2001 thundercat 99xcr 800 97SPX ULTRA 96 zrt 600&800,92 doo plusX 92 v max 4 750
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October 23rd 2009 at 3:22 PM
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Killa580EFI
Starting Member
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15 Posts
Group: Members
Member Since: October 14th 2009
Location: S.C., Sask, Canada
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Quote originally posted by stormrider62033
those are coated bores make sure there ok ,if not need them recoated or sleeved
Update:
well I took off the heads and found something NASTY my Pistons will have to be placed I have pics of them.
What do I do Next ?
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October 23rd 2009 at 5:30 PM
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Empire087
Dude wheres the snow?
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237 Posts 
Group: Members
Member Since: July 19th 2009
Location: Sault Ste Marie, Michigan
Current Sled: 2002 ZL 500
2008-2009 Miles: 475
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Looks like it got a little warm, When i replaced pistons i had both the jugs off. What i did is a put the pistons on the crankshaft put a ton of oil in the cylinders(always replace in sets) then put the jug on over the piston while holding the rings in position, once both were in i grabbed the torque wrench and tightened the jugs back in place to the recomended specifications, then did the same with the head. Just gonna give you the heads up, when your breaking it in make sure you use standard mineral oil for the first 150-200 miles or two gallons of oil to break the rings in properly. I didnt do that and i need to do it this year, hopefully my rings made it.
02 ZL 500(apv)
91 jag afs 440
"if it snowed in the summer, I'd ride!"
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October 25th 2009 at 6:52 PM
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Killa580EFI
Starting Member
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15 Posts
Group: Members
Member Since: October 14th 2009
Location: S.C., Sask, Canada
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Quote originally posted by Empire087
Looks like it got a little warm, When i replaced pistons i had both the jugs off. What i did is a put the pistons on the crankshaft put a ton of oil in the cylinders(always replace in sets) then put the jug on over the piston while holding the rings in position, once both were in i grabbed the torque wrench and tightened the jugs back in place to the recomended specifications, then did the same with the head. Just gonna give you the heads up, when your breaking it in make sure you use standard mineral oil for the first 150-200 miles or two gallons of oil to break the rings in properly. I didnt do that and i need to do it this year, hopefully my rings made it.
Update:
Well today i took the head off and took some pics of the piston it self.
Here are some pics of what i found, where can i find a piston kit for a good price?
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October 25th 2009 at 6:59 PM
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stormrider62033
wally
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4729 Posts
Group: Members
Member Since: December 25th 2004
Location: Gillespie, IL, USA
Current Sled: 99xcr 800
2008-2009 Miles: 500
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better check to see if you have a big air leak some were wow
mid Il alway's waiting for snow,moving north(way north)2001 thundercat 99xcr 800 97SPX ULTRA 96 zrt 600&800,92 doo plusX 92 v max 4 750
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October 25th 2009 at 7:01 PM
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Killa580EFI
Starting Member
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15 Posts
Group: Members
Member Since: October 14th 2009
Location: S.C., Sask, Canada
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Quote originally posted by stormrider62033
better check to see if you have a big air leak some were wow
Where would i look for an air leak?
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October 25th 2009 at 7:26 PM
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stormrider62033
wally
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4729 Posts
Group: Members
Member Since: December 25th 2004
Location: Gillespie, IL, USA
Current Sled: 99xcr 800
2008-2009 Miles: 500
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man the boot main seal or crankcase mating surfaces ,that baby is toated
mid Il alway's waiting for snow,moving north(way north)2001 thundercat 99xcr 800 97SPX ULTRA 96 zrt 600&800,92 doo plusX 92 v max 4 750
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