Finally, I have left the disassembly stage, and I started putting the engine back together again. Truthfully, I was really nervous about whether everything would come back together again. In reality, it all pretty much fell together, and though I had some brain farts along the way, it took a fraction of the time I thought it would.
Important lesson learned… before putting the case halves together, make sure you apply the Hondabond!!!! I will just use the excuse that I was test fitting everything!
The Kickstarter and Shift Stop Cam Assemblies
You can see the new Oil Seal and the Circlip inserted, making sure it is sitting in its groove.
Here is the Shifter Cam that fits on the Gear Shift Drum. I used blue Lock-tite and made sure the knock marks on the screw lined up with the marks on the Cam Plate surface. I cannot get it any tighter than it is, so I will have to assume its OK. There were no torque specs given for it.
Here is the Shift Fork Assembly. After a few tries, I realized it had to be assembled as the Gear Shift Drum is inserted into the case, attaching the shift forks one at a time. This took me a few times to get it right. I kept the manual in front of me to make sure that everything went together correctly.
Another view of the Shifter Cam. I just had to be careful to get the orientation of the springs correct, but it’s a pretty straight forward assembly.
Starting to look like an engine!!!!!!! However, I forgot to apply Hondabond to the case halves, so this would all come apart again in the morning.
Clutch assembly and oil pump in, after I disassembled the case halves and applied the Hondabond.
Assembly Lube on the Connecting Rod Bushing surfaces.
Pistons installed!!! Ok, second big lesson…. If your Cylinder Head Studs are in, make sure you install the Pistons so that they are in the middle (i.e. The pistons do not fit through the gaps between the studs!!!) Damn… those piston pin clips sure can fly along way very fast!!!!!!!! Luckily, I found it.
Also, make sure you put on your gaskets before doing anything, and test fit to make sure of their orientation – again, ask me how I know! Anyway, a bit of Hondabond, and the crankcase to cylinder gasket was on.
So I had to leave it here. I had a ring compressor, but it was one piece and won’t work in this situation. I need to get hose clamps and install the pistons into the cylinders this weekend. So I carefully covered everything, as I had lubed up all the surfaces thinking I was going to get this done.