Topic: Mainshaft needle bearing guide pin... Problem?

[Dimitri13]

Okay so through the three or four test fitments of the cases I had, there was no problem with it. This time, I took out the main and counter shafts to install the shift drum pin clip (pin fell out last night because I forgot the clip), I noticed the guide pin to keep the needle bearing's race in place is somehow pushed flush with the case. I test fit the cases just to see if maybe the race would stay put when all the bolts were installed and torqued, and so far, it doesn't look good.

I assume it's important for it to be in that position, as it looks like it's part of the oiling path.

How am I supposed to get the guide pin out of the case? I can't get any purchase on it with pliers. The only thing I can think of (without damaging it) is to heat up the case and hope it falls out or pull it out with a magnet.

After that, then what? Are the countershaft and mainshaft needle bearing guide pins different lengths? If so, it's possible I got them mixed up, as they were both out and I needed to replace one because one fell out of the case at some point.

I assume putting maybe a few washers or some sort of spacer would be enough to get it up?

p.s. this is very frustrating as it's the fourth or fifth setback I've had putting the cases together.

[Dimitri13]

Ugh nevermind.

Turns out the race got turned at some point and pushed the guide pin THROUGH the case a bit. I'll have to have my welder friend fix it or maybe JB weld?

[HondaMan]

Ugh nevermind.

Turns out the race got turned at some point and pushed the guide pin THROUGH the case a bit. I'll have to have my welder friend fix it or maybe JB weld?

Can you drill a smaller hole from the opposite side, and maybe tap it out from there with a nail or small punch, or something? Then the hole can be plugged in many ways afterward.

[Dimitri13]

I was able to get the pin into position. You can see in the picture if you blow it up, the part of the case has been pushed out by the pin. That piece completely came out.

What would you recommend doing to fix the hole? Keep the piece in there, then weld/epoxy it into place, or remove the piece and fill the hole with weld/epoxy?

[HondaMan]

If it's not an oil feed passage, I'd thread it and install a small setscrew, then peen the case edges over it to prevent it ever backing out. It may have to be a real short one?

[Dimitri13]

Unless there's such thing as 90 degree taps, I'm not sure I can thread it. The horizontal threads protrude further out than the hole.

[dave500]

it was posted not long ago someone had a similar problem,the pin had been pushed through the otherwise blind hole,just push it back out somehow and jb the hole,have you worked out the cases go together easier without all the seals in place yet?

[Dimitri13]

Nah it seemed fairly easy to assemble the cases with the seals in place. Everything's as it should be except the pin issue and trying to figure out how the shifter mechanism stuff goes.

Pretty hard after 11 months and no pictures.

[Oddjob]

It's so easy to do this if your not careful. In fact I always assemble the engine upside down now, that way you can locate the bearing dowels, you can get the selectors engaged with the gears. The only thing about this method is that you need to have the primary shaft out of the bottom half of the case, however it's so much easier to fit the shaft afterwards I'm surprised Honda didn't show this method originally.
I always have all the seals in place, the crank seals need to be installed because they are lipped, whilst all the others can be installed afterwards it's easier to install them when the cases are apart, that way as the cases come together they are slightly crushed, you don't need sealant on the edges, in fact I've never used sealant on a seal ever and I've done more engine rebuilds in my career than I care to remember.

If you need a tool to pull the primary shaft the bottom engine hanger bolt fits perfectly. I used to leave a footpeg on it and use that as a slide hammer.