First time Harley builder and am finding out the circlips are quite a challenge to install. Whats the trick to installing without a circlip tool? I see the potential of gouging out the piston pin bores and or putting your eye out.

 

Sounds like you found the way to do it without the proper tool, gauge the piston, flys through ths air and hits you in the eye and bounces off your face and into the bottom of the crank case. The next step is to try a different approch or you could go rent the proper tool.

 

Use, a piece of copper pipe and install the circlip in the copper pipe, then push the circlip into the pistonwith a socket on a extension, hope this makes sense, maybe some one has a picture. Todd

 

Good idea! never thought of that. The OE clips are easy to work but the Aftermarket pistons clips are bastards!

 

That's FUNNY!!!!!!!!!!!

 

You can save yourself the trouble of trying to buy the HD specialty tool shown in the Service Manual that has an HD part number--HD doesn't sell the circlip installer to civilians, nor does HD's vendor.

 

I have used the copper coupling and I have found that if I use a thin pair of needle nose pliers and a small screw driver that I can do it just as easily. make sure you have clean rags stuffed in the case holes. It also helps if you have an extra pair of hands holding the piston/rod still. The KB pistons have cool spiral locks that are really nice and I wish they all had them.

 

I never thought of the pipe thing, but it makes perfect sense. Thank you so much for the help. Now I'm convinced as to why I come to this forum for help. The money you just saved me on another specialty tool will now go to a paid membership here. Thanks again. Jay