Bob is my uncle.
4 hours turned out to be more like 8 to get it all reassembled, working slowly and carefully, torquing everything, all that jazz. Along those lines the manual is very thin on some of the torque specs, so I reverted to Honda default values for fasteners of a given size.
My buddy James (Harisuluv) came over last night and helped put the case halves back together and we installed all new seals, and those new bearings. We used Gasgacinch to seal the case halves and I am friggin' delighted to share that there are zero leaks, nada, not from the case halves, not from any of the seals, nothing. It is tight as a drum.
Everything went pretty smoothly but I have to say, if I was to try and make a living installing exhaust systems, I'd starve. I bet I spent the better part of an hour getting that thing on. Must remember to go back and re-snug the flange nuts.
Put it all together, primed up the carbs a bit, and had the temerity to take a video:
Very happy to have this sorted.
Took the bike for a quick mile around the neighborhood, and it's revving fine and shifting fine, although a bit notchy and neutral was a little hard to get. I think it's a simple as a clutch and chain adjustment though. Very psyched to put a few hundred miles on it and break things in, remember it had a grand total of 20 miles on it since the APO did hid 'rebuild' of the engine and it puked oil on my foot, so it's still tight and needs some running.
VERY HAPPY. Did I say that already? Many thanks to Harisuluv and Thirsty 1 and MoMo all of you guys that offered suggestions and advice and encouragement along the way. It's been a fun project mostly, even with the Easter eggs the APO left for my discovery, and I am glad to finally be in the fine-tuning stage. I'll cap this thread off soon with some beauty shots of the bike here in the desert, but for now here's a few from today's work.
Shifter reassembled.
Rotor reinstalled, cleaned up and WD-40'd
Clutch holding tool:
Kick-start gear reinstalled. I can do this, but I cannot tell you how :-)
Prepping gasket surfaces. The bane of all of our existence.
Closer...
Installing and timing the C5 ignition
Ready to fire up again!
