Topic: Engine rebuild guide/tips?

[Dimitri13]

I think I need to do a complete engine rebuild. I have multiple leaks (head gasket, valve guides, cam cover, tappet covers, oil pump, and at least a few others), oil flow issues, unusually stiff clutch, some sort of transmission issue, and I want to do a few other things (port/polish intake, paint/polish engine, and possibly bore).

Any threads covering a complete rebuild, diagnosis, and prettying up? I tried searching a bit but couldn't find much. I already have a clymers, haynes, and access to the honda shop manual, but I'd like some input.

Where is a respectable place to get a rebuild kit? I know there's a bunch on ebay, but I don't trust them for something like this.

Thanks in advance

[fastbroshi]

  Hondaman's book on the 750s may be a good place to start.   They may not be a lot of info that specifically pertains to the 550s but the methods used to rebuild and maintain them are similar.   

[Dimitri13]

Thanks. I may pick up his book.

Still looking for suggestions on where to get an engine gasket kit.

What hard parts should I expect to replace?

[fastbroshi]

As far as hard parts, it all depends on what you have when you start inspecting things.  If you plan on going for a bigger bore, pistons and rings are oviously needed.   A new clutch pack is a definite, new sprockets and chain, cam chain, primary chain.   The crank bearings are pretty sturdy but have failed so check and recheck those as well as the crank for wear.  You mentioned valve guides, that would be a gotta have along with a valve job.  Make sure to inspect the cam and its saddles carefully for wear.    If your transmission dogs spec out then your probs there might be sourced to poor clutch adjustment.   There's several bearings that reside in the case that may need to be replaced too.   Check your parts diagrams carefully for any seals for the case that need to be replaced.