Author Topic: Project: 7-Fizzle - V1.1 - If only spring would get here... (Read 149518 times)

iron_worker · « **Reply #150 on:** January 06, 2013, 07:27:48 PM »

So hopefully this time I can put a coherent post together without deleting all my pictures from photobucket and the thread itself...

I saturday I started tearing into the cases ... nervous to split them but here we go:

Just noting where all the various hardware and clamps and such go. This is the over flow tube holder.

Cable holder near the drive sprocket.

4 longest bolts go here.

Very rear right threads directly into the case.

Center rear with tube holder has a nut.

All the top side bolts...

Oh wait ... dug one out of 1/4" of grease on the left side. Also has a nut.

To the other side...

Noting the wire tabs...

4 equal length, 2 longer are on the outside ends.

Two long ones near the alternator.

All the bottom side bolts.

Neutral sensor and clamp bolt ... which allows you to remove the shift drum.

Oil pump and hardware.

After some whacking with mallets and wood blocks etc ... they separate!

Top half looks pretty clean. Mains look nice.

Interesting ... now what...

Center crank journal. The flash makes the lines look like grooves but you can't even feel them.

Mains look nice in the top half.

Shift forks out.

All the wear pads look pretty nice. No gouges or scratches.

Shift drum and shift fork.

Roll pin that holds the kickstart gear in place was a bit of a bear. I used vice grips to "close" the roll pin as much as possible.

And ever so slowly rocked it back and forth until...

It finally popped out!

Oil catch tray that sends oil to the auto lube for the drive sprocket. I think I'll leave this out since I run an o-ring chain.

Fruits of my labor. I haven't torn it completely down yet but everything looks pretty good thus far.

A neat shot I thought.

A peak of the mains from the top half.

Closeup.

Anyone know where this is from?!?!?!

Looks like a dowel pin but not the same size.

Break out the plastigage.

I actually ended up checking the mains twice because the crank slipped and spun around the first time ... the second time I offset the plastigage to avoid the oil hole.

Reassemble and torque to 17lb*ft.

This was main closest to the points and had the widest tolerance.

Working across the tolerances got a bit tighter.

As tight as .001 on the alternator side.

#4 rod bearing opened up.

#4 - .0015"

#3 down to .001"

#2 rod - .0015"

#1 rod - .001"

DISASTER!

Overall I was pretty pleased on saturday. Most of tolerances are within factory new spec and all well within serviceable limit. The bottom end shall remain untouched other than a crank balance.

I'll post up my Sunday's work in a moment.

IW

iron_worker · « **Reply #151 on:** January 06, 2013, 07:34:14 PM »

Today's focus was to get the cases cleaned up and build a crate. Here is how it went down:

I started by creating another huge disaster.

A lovely crate which is really fricken heavy.

It's 100lb without the top. Uh oh.

Case bottom after the power wash. I had to be sneaky at the car wash. lol Believe it or not this is a big improvement.

The top cleaned up pretty well.

So much nicer to handle without 1/4" of grease.

Organization and floor washed!

Gotta put stuff away as much as possible at the end of the day.

Sooo .... I know I over built the crate but I wanted to be sure it would get there undamaged. I'm worried that the price to ship this bad boy is going to be several 100 $... Tomorrow I'll call around for quotes I spose.

I could rebuild the crate lighter or just send it in cardboard boxes but I've already spent the money on this wood... I guess if shipping cost is too crazy I may just have to find a local machine shop. I was hoping to go with CycleX though because they seem to know damn near everything there is to know about these old engines and how to handle them.

I also am going to start repairing all my broken picture links but that could take a while... frick I'm mad at myself about that!

IW

dave500 · « **Reply #152 on:** January 07, 2013, 12:36:46 AM »

is that larger looking dowell for the oil pump,it forms the body the o rings sit into?is there three of them?

iron_worker · « **Reply #153 on:** January 07, 2013, 05:58:42 AM »

Ah you could be right Dave. I'll check that! Thanks.

IW

theofam · « **Reply #154 on:** January 07, 2013, 06:29:28 AM »

I'm w/ Dave500 - my first thought was it's one of the oil pump dowels. Great progress on your build! I can't believe you're doing it three stories up - that's dedication! I may speak for all of us in saying I'm looking forward to 7-Fizzle's descent back to terra firma.

You asked for advice with regard to media blasting the cases. Make sure they're using plastic and not glass, as glass can impregnate the aluminum and later pop out when the engine heats, making your hard-earned paint job look like junk. Also, make sure you clean the snot out of it afterward. I overlooked the oil galley and promptly seized my beautiful motor in 15 minutes (plugged the galley orifice that fed the 1/2 cam side). Just be meticulous, and I think you'll be happy with it.

Keep chuggin' - great work so far!

jgmmgood · « **Reply #155 on:** January 07, 2013, 07:42:26 AM »

splitting up the pieces may actually save shipping costs. Prices seem to go up asymptotically when you excede 70 or 75 pounds. (may be an option....)

iron_worker · « **Reply #156 on:** January 07, 2013, 11:44:53 AM »

Yeah that's something I'd considered was building to different crates. Canada post only takes up to a max of 66lb. Fedex and UPS will take it as is though. So we'll see.

I'm still waiting for that M20x1.5 bolt to come in so I can get the starter gear off ... it's just a touch too tall for the crate. pretty sure they won't need that for balancing?

IW

iron_worker · « **Reply #157 on:** January 07, 2013, 05:54:34 PM »

Dave Theofam ... you are indeed correct. It is the oil pump dowels. Where would I be without you guys!? lol

Also ... I just finished fixing *ALL* my pics. Deleted all the pics by mistake ... had to reload them all to photobucket and then fix all the links. ARG! 2 hours of my life I'm never getting back and was absolutely pointless. ha

IW

UK Pete · « **Reply #158 on:** January 08, 2013, 06:31:12 AM »

Well documented IW, it will make things so much easier when you reasemble, the inside of your engine is very clean and with minimal wear, that is good news for you as you only need replace things like chains and tensioners
Keep up the good work fella
Pete

iron_worker · « **Reply #159 on:** January 08, 2013, 07:15:02 AM »

Yes my father and now I have always been diligent with oil changes and I think it shows.

Thanks for the props.

IW

iron_worker · « **Reply #160 on:** January 08, 2013, 12:07:08 PM »

Anyone buy/install the side covers from this guy?

http://www.fb-stuff.com/fb-stuff-store.html

They look like good quality but it's hard to say sometimes with stuff like that and only a picture.

IW

Scotty J · « **Reply #161 on:** January 08, 2013, 12:56:55 PM »

(Just read through beginning-to-end on a slow work day)

Still looking for rear grab rails? I've got a set in good nick that I'd part with. I'll throw up some pics when I get home. I've also got some crash bars that came off along with the grab bars, if you're interested.

FBstuff is a member on here-- "The Honorable Mr. FrankenFrankenstuff" Profile: http://forums.sohc4.net/index.php?action=profile;u=15761.

Garystratos201 · « **Reply #162 on:** January 08, 2013, 01:25:44 PM »

Very nice worl IW.........Gary

iron_worker · « **Reply #163 on:** January 08, 2013, 01:28:39 PM »

Thanks guys. And yes I'm looking for a rear grab bar still so throw up a pic or two when you get a chance.

IW

iron_worker · « **Reply #164 on:** January 08, 2013, 05:51:56 PM »

Well I took a night off the gym and I tinkered around a bit more. Seems a bit unproductive because I feel the need to clean everything up when I'm done... on week nights that only leaves me an hour or so to work. Ah well. Every bit helps I spose.

Bagged and tagged and boxed the stuff that came from splitting the cases.

Like it was made for this box!

Finished building my crate. Just need that M20x1.5 bolt now so I can get the starter gear off since it's a bit too high for the crate and not needed by CycleX for balancing purposes.

Some nice rope handles and the obligatory "THIS SIDE UP" labels.

I'll throw in some more packing before I ship it off fo realz.

Popped out the secondary shaft bearing with these bad boys. Came out pretty easy actually.

Pulled out the bearing shells. Gettin ready for blasting of the cases. I may have mixed up one or two of the uppers and lowers ... hope this doesn't matter!

Split bare cases.

The beauty of having a 20gal parts washer... the whole lower half fits.

And can still fit the upper half on the shelf to store it away nicely!

Found out that my zinc plating kit fits nicely on the bottom shelf of the parts washer. Saves me some floor space.

A project I'll need to tackle soon ... de-spoking these bad boys. They will go for blasting with the cases.

And cleaned up once again.

Always lots of odds and ends to do in a project like this...Infinite odds and ends!

IW

mwvachon · « **Reply #165 on:** January 08, 2013, 07:44:35 PM »

Looking good there, iron_worker. I'm just about there with you on mine.

iron_worker · « **Reply #166 on:** January 09, 2013, 06:12:13 AM »

Thanks! And good luck on yours.

IW

MJL · « **Reply #167 on:** January 09, 2013, 02:21:45 PM »

Quote from: iron_worker on January 08, 2013, 12:07:08 PM

Anyone buy/install the side covers from this guy?

http://www.fb-stuff.com/fb-stuff-store.html

They look like good quality but it's hard to say sometimes with stuff like that and only a picture.

IW

He's a member here, The Honorable FrankenFrankenstuff IIRC. Yes I have bought a pair of his covers, they looked a bit rough on the inside but they fit perfectly. I need the logos to put in mine though. Various people make stuff, sticker emblems, jewels, etc.

iron_worker · « **Reply #168 on:** January 10, 2013, 06:01:56 AM »

Well guys last night I put the finishing touches on my crate, made sure stuff was jammed in place with Styrofoam or cardboard, and sealed the lid on. This morning I carried it down the stairs and loaded it into my truck ... I'll head off to Fedex over noon.

Holy hell it's heavy going down 3 floors with 100lb awkwardly shaped box.

I also put my $18 bolt to good use and got my alt/starter gear off. Easy when you have the right tools.

I spent a bit of time cleaning up the lower case as well.

I had pics of it all but last night the forum was down or something so I couldn't post! I'll try and get them up tonight.

IW

iron_worker · « **Reply #169 on:** January 10, 2013, 06:09:58 AM »

I also just stumbled across this color chart for CBs and thought it could be very useful.

For future reference: http://www.motorcycleproject.com/motorcycle/text/lubrtech.html

IW

brandEn · « **Reply #170 on:** January 10, 2013, 07:08:24 AM »

This is an awesome build and your doing a great job documenting. It seems like shipping those parts in that wood crate is going to be $$$. I would ship them the way APE performance recommends. Check out this link.
http://aperaceparts.com/packaging.html

This will probably save you some serious cash. Remember you have to pay for the shipping back too!

iron_worker · « **Reply #171 on:** January 10, 2013, 08:49:52 AM »

Ya it's going to be about $150+ each way but in that crate I know it will be safe and get there undamaged. Worth the piece of mind in my eyes. They could literally throw it and drop it and I don't think it would hurt anything.... though I hope they don't. lol

Thanks for checkin out my thread.

IW

iron_worker · « **Reply #172 on:** January 10, 2013, 02:59:49 PM »

Pics from yesterday:

The lovely M20x75mm, 1.5mm pitch, highly elusive, bolt.

Tighten it on a bit, couple whacks on the end of the bolt with a hammer, tighten it a bit more, and voila!

Starter gear pulls right off.

Grease up the journals for rust protection during transport.

Everything is packed tightly. Snug as a bug.

Thought I would give removing that broken stud one more shot... I welded a piece of 1"x1/8" bar onto the end of the stud... I just sheared off the next 1/8" of the stud. It's really stuck!

I even heated the case around the stud!

I cleaned up the lower case half in the parts washer.

Got most of the junk off of it.

Even got down in the nooks and crannies.

Inside looks pretty nice.

Top half now soaking awaiting it's turn.

My secret tool for cleaning nooks and crannies ... a piece of steel wool wrapped around a drill press. Actually works quite well.

Today I also dropped off my crate at FedEx. My stuff will be with CycleX by the end of next week I hope. Excited to start the engine build but don't want the bill for the parts and machine work. ha

IW

Scotty J · « **Reply #173 on:** January 11, 2013, 04:31:33 AM »

It's in good hands with Cycle X. I just recently swapped my alternator rotor for their lightened/balanced one, and they thankfully included the rotor extractor bolt in the kit. No idea how I would've popped it off without that. PM sent, BTW.

iron_worker · « **Reply #174 on:** January 11, 2013, 05:54:36 AM »

PM returned!

And yes, there were a few reasons I wanted it to go to Cycle X ...

1) They focus on SOHC Hondas ... and mainly the 750. With a market sector that focused I figure they must know all the little tips/tricks/secrets to do the work right.

2) I'm ordering their "Git Kit" from them anyway so they can bore and hone the cylinders to those pistons specifically and send them back.

3) I'm paranoid.

IW

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Author Topic: Project: 7-Fizzle - V1.1 - If only spring would get here... (Read 149518 times)