Topic: Chronicals of my 550 rebuild - over a month in with one day to go! PICS!

[Tim.]

My intrepid 550F is coming back from the dead.  After tearing the engine down at the end of August, and waiting weeks and weeks for shipments of pistons and gaskets from the US (would you belive both Classic Cycle Parts and Western Hills Honda forgot to ship my stuff for 2 weeks!) I'm THIS CLOSE to getting it back on the road.

Today I put the new pistons and jugs on.  Changed out two studs, drained the oil, new filter, dropped the oil pan etc.  I had to drop the pan as a stubby 12mm wrench I was using slipped and jumped straight into the engine!

Tuesday I pick up the head.  Unfortunately the head wasn't ready on Friday, and it's a long weekend up here which just makes things even more frustrating.  That and unseasonably warm weather.  Sheesh.

[Tim.]

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[Tim.]

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[bwaller]

Looks like things are coming together, too bad you missed out on riding today, it sure was a beauty. Hopefully there will be more days like this one.
  It seems like you haven't used any oil on reassembly. Maybe you took some dry photos first? 

[Tim.]

I've been using oil, but not loads and loads of it.  Maybe not enough - this is the first time I've done this.  Last time I paid to have it done (was only 3 hours extra on top of an already huge bill and the bike was in pieces at the shop, so not much choice!).

I was concerned with slathering the pistons/cylinders with oil, but maybe more concerned than I should have been.  By the time I got to putting it together, everything in my garage including me had a nice layer of oil on it, so things went together pretty smooth.

I did slather oil all over the rods and wrist pins and gave the rings a nice coating as well as the piston sides and the bottom end of the cylinders.

I didn't use a ring compressor - didn't have one that fit in the tight space and that could be taken apart to remove.  Most are designed to let you push them into the cylinders from above.  How on earth does one rebuild a V8 engine anyhow?

I'm looking forward to getting the head back.  I just want to ride.  I've got a Dyna ignition in the meantime, but will add that on later.  I'm replacing the carbs with a fresh set as well, and don't want to change too much all at once.  The timing and points/condensers were all done new last spring.

[bwaller]

Good work, you don't need much oil. Hopefully you'll have better luck this time around.

[Jinxracing]

How on earth does one rebuild a V8 engine anyhow?

Never done a V8 myself, but when I've seen it done they let the rod hang from the wristpin and insert the piston/rod assembly from the top end with a ring compressor. Once that's in, then fit the big end of the rod on the crank and attach the cap. Needless to say, lots of rags and a steady hand are a good idea to keep that rod end from banging into the cylinder walls and crank journals!

[Sam Green Racing]

Jinx, I think you'll find there a bit tougher than that ....have you ever seen a top fuel drag crew rebuilb a motor.

If you think the cars are fast, just watch the mechanics

Sam.

[Roastem]

man all I have ever rebuilt is V8 engines, i got a stang runnin low twelves... but lookin at those pics, i am tryin to figure out if I am goin in over my head rebuilding the 550 engine.....

[Tim.]

I've NEVER done this before, and it took me 1/2 hour to put all the pistons on the rods and swap out two studs.  Then some fiddling with the cylinders - no ring compressors.  Would have been a lot easier and faster with ring compressors, but my fingers and the tapered ends of the sleeves got the job done alright.

Just anxiously awaiting the head - will pick up tomorrow and then maybe tomorrow night I get it running again.

[MotoRico]

Did you put the new pistons and cylinders in with the motor still in the frame?

[dusterdude]

man all I have ever rebuilt is V8 engines, i got a stang runnin low twelves... but lookin at those pics, i am tryin to figure out if I am goin in over my head rebuilding the 550 engine.....

OH GOD NOOOOOOOO!!!!!!

[Tim.]

Did you put the new pistons and cylinders in with the motor still in the frame?

Yep - beauty of the 500/550 design.  There's plenty of clearance to work - no reason to pull the engine.

[Tim.]

Got distracted this morning and bought this for my wife, who has finally realized the appeal to 2 wheeled travel.

[MotoRico]

Got distracted this morning and bought this for my wife, who has finally realized the appeal to 2 wheeled travel.

Does the Hot Wheels sticker make it faster? 

[Jinxracing]

Jinx, I think you'll find there a bit tougher than that ....have you ever seen a top fuel drag crew rebuilb a motor.

If you think the cars are fast, just watch the mechanics

Sam.

I've tried to watch them, but they move so effing fast all I can see is a blur! The only time I've ever gotten into a bottom end was in my old '64 VW van...oh yeah, rebuilt the motor too. 

[putnaja1]

Hey, CB lookin good tintin!  While we're on the topic of 550 motor rebuild,

Can someone explain to me why you have to hold up all the valve tappets when you put the valve cover on?  I know it's so you won't bend a valve, but how could a cover that can be in place when the motor is running possibly push down the valves when you are tightening it?   

[Tim.]

Because when the cover is off, all the valves are in the closed position, which is never the case when the engine is all in one piece.

You'd be forcing the valves into open positions, at least some of them if you simply put the valve cover back on without backing off the tappets.  Because the tappets and valves aren't aligned properly when you're moving the valve cover around, they will likely bind and you'll end up bending stems.

The only way to do it really properly is to back off all the tappets completely and then work through the valve clearance procedure to tighten them all back down to their proper positions as you run through TDC for each piston.

[Tim.]

Well, we're getting there!  One more session and it should be back on the road.  Took me 5+ hours to do the following:

[Tim.]

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[Tim.]

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[Tim.]

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[Tim.]

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[Tim.]

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[Tim.]

So in summary, for my 5 hours I got a decent amount done - took my time, but it's getting there and no issues thus far.

I have a Dyna in the box, but don't want to introduce too many variables into getting it running again.  I'm using a newly rebuilt set of carbs that I've never run, along with a new MAC muffler I picked up.  The points/condensers/timing were all done 2000 miles ago, so I know they're in good shape.  Will put the Dyna on in the spring I think.