MMMMM yeah sorry
I should have pointed out the burrs around the circlip groove, you wouldn't have got that pin in with those there (see surface damage in last photo). I made an assumption
that they would be removed?, it would be some thing I would have removed without thinking about it.
Those gudeon pins are a transitional fit, which means they would have slipped in & out of the piston with "relative" ease yet with no play (looseness) what so ever. As you were re-using the old piston and pin it "shouldn't" have given you the grief that it did.
When fitting the new piston ONLY attempt to fit the clip ON ONE SIDE ONLY, so you dont damage the OTHER pin bore. Slip the pin through the first piston bore (which you havent touched, hence undamaged), push through the conrod small end (you may have to jiggle this a little to settle the needles if a needle roller bearing fitted) and make sure the pin has gone through far enough before fitting up the last circlip. Check your circlips have seated well in their grooves and your there! The WARM and COOL trick JOE & GRUMPY pointed out will help, but shouldn't be required unless the rod is a shrink fit onto the pin
(check first). Remember keep every thing cleaner than clean too....a fiber off a rag will stuff up the transitional fit...
[u][/u]
