Finally got everything all buttoned up!
The blank canvas...
Permatex FormAGasket 2 goes in the recesses, then the 0.030" shims.
Then the pucks had a bit more Permatex put on their edges, and sat down into the recesses. Pressed them down as much as I could to force out any excess, then cleaned up.
Cam towers in place, before timing the cam... Thanks again, Rafi! Definitely the best way to get the cam chain, sprocket, and shaft in place can be seen in Dean's video...
Put the bearing caps on after timing the cam. Oil goes into those little recessed holes as you put it together! At this point, after releasing the cam chain tensioner, I decided to use the kickstarter to make sure I had oil coming up to the top end. YEP! Sure do! Took about 30-40 kicks to see it spurt out of those little holes. Having the spark plugs out really helped!
Everything all in place now, before setting valve clearances. I left out the 5mm rocker shaft retaining bolts, as recommended by HondaMan. I did go through and check to make sure each shaft's oil groove was visible with side to side motion of the shaft when the bolts are in place. Only one had to be widened, thankfully... #2 EX.
Valve clearances were set according to the book. 0.002-0.003 for intake, and 0.003-0.004 for exhaust. Setting valves, for those who have never done it before (LIKE ME!) is pretty straight forward. What I did was go for the smaller of the two numbers. Tighten the adjuster down LIGHTLY onto the smaller feeler gauge. It should slide in that space with some friction, but not stick. Tighten the locking nut. Check once again... the smaller one used to set the spacing should slide back in with some friction, but the larger should not go at all (or maybe with a good pull through).
After a restless night...
Upon putting the valve cover on, I forgot that I had not replaced these two screws, and they were all stripped. I managed to get them to approximately (by feel) 90 in-lbs using vise grips. Going to get some socket head M6x80mm bolts on Monday and take that breather cover off again.
And here it is, all buttoned up. Frame section put back in, too. I'm going to swap the front two frame clamps so the bolts are facing out on the bottom, rather than angled like this because of the coils.
Everything went back together after this... carbs, airbox, etc... She fired right up! No problemo! I'll post more pics, obviously, once I get those other screws replaced in the breather box. Thankfully not much has to come back apart to do those screws. It was nice to hear Rhonda sing again!
