So I'm working on rebuilding my top end on a 97 trail boss, I got the cylinder head off, and removed the clips on both side of the piston, but I can't get the damn sleeve out. I've tried a socket and a hammer with a few light taps. I was scared to.beat on it too hard, I don't want to mess the rod up. How the hell can I get it out? I was thinking a c-clamp and sockets on each end. Any ideas?

I also have a good bit of metal dust in the bottom end, is it safe to.pull the 10mm crank case plug and flush the metal out with mixed gas?

 

On really tough piston pins that have galled in the rod a good piston pin puller will do the trick. If you are replacing it with a new rod kit(probably needed if it's this hard to get out) just use an impact hammer with a small bit to drive it out. Plus if you hold the piston firm while using the impact you probably won't hurt the rod if you intend to reuse it. http://www.ebay.com/itm/Motorcycle-Snowmobile-ATV-Piston-Pin-Puller-2-Stroke-4-Stroke-Dirt-Bike-12-1026-/300674915319?pt=Motorcycles_Parts_Accessories&hash=item46019f1bf7&vxp=mtr

 

Don't really have access to air where I'm working on it. Would some all thread with a deepwell on one end and wrist pin size socket on other work? Neither side of the piston looks galled. I might try to.rig up a puller and see what happens, maybe apply some heat to it. How can I get the metal dust out, without splitting the case?

 

All thread is basically will work in the same principle as the piston pin puller. If the pin is this hard to pull it's not allways just the piston that's galled but a lot of times it's also the inside of the rod itself! If you're going to this trouble,I wouldn't do just a top end only! Flushing an engine case is no guarantee you'll get all the metal particles out,plus make sure the rod has no up and down play on the crank and no noise or roughness from the crank bearings.I've just seen too many bottom ends take out a new high $ top end when people do a partial rebuilds on 2 strokes.