Topic: Difficulties with putting crankcase together.

[jasonseasen]

Hi,
I am at the point of putting the crankcases together. I had placed the final shaft into the upper case and bolted in the final shaft oil guide. When I try to flip the upper case over to place on the lower, I find that the final shaft and its set ring disconnects with the upper case. I am finding it hard to hold the final shaft up into the upper case as I try to place everything onto the lower case and deal with the piston rods.
Any tips?
There is something different needing to be done with the final shaft so it does not fall out like that?
Thanks,
Jason

[Hannibal Smith]

I could pretty easily retain all the junk in the upper with my fingers, with my thumbs on top and had a buddy guide the rods through the upper case. Just remember to have the crank seals settled perfectly in the lower half, if you bump one and it gets cockeyed, start over and inspect the spring in the inner lip. The shoulder is small.

I posted what can happen, and had to tear my assembly back down. Granted it was easy, but still.

Edit to add- Maybe it is the sign of the times, but I have never heard of so many Lone Wrenches in my life..............where are your pals, fellas?

[jasonseasen]

Thanks Hannibal.
Is it normal for the final drive to fit so loosely in the upper case and fall out like that? 

[Hannibal Smith]

It should just set in there, and will fall out if inverted. I have big hands though, and could easily hold things. With those retaining "half rings", all said and done it is probabbly best to do what you have been doing.

I also had my crank rotated to allow the maximum con-rod height across the board, and we didn't have any issues.

There is probably some trick that I have no idea about, but it was easy for me, and I had to do it twice!

[mystic_1]

On a 750, I always put everything into the upper case, which is upside down, then put the lower half down on top of it.


mystic_1

[jasonseasen]

Mine is a 750, forgot to mention.
Wondering if anyone else had success with the guts into the upper case trick?

[mlinder]

Mine is a 750, forgot to mention.
Wondering if anyone else had success with the guts into the upper case trick?

Best to start assembly with upside down upper case, then pop on lower case, as mystic says.

[MCRider]

Mine is a 750, forgot to mention.
Wondering if anyone else had success with the guts into the upper case trick?

Yes, sounds like you've got the wrong method. EVERYTHING, especially the crankshaft and connecting rods, you possibly can, goes in the upper case which is upside down on the bench. Then you simply put the bottom case on.

Much easier, I can't even imagine the difficulty of doing it otherwise.

And since it is likely you may not know, the main bearing bolts go in first, torqued to a pattern from the center out. Then the smaller bolts working your way out to the edges.

Then flip it over and finish off the bolting.

[mystic_1]

The transmission countershaft, shift drum, and shift forks all go into the lower case but they won't fall out when you flip it over.

This is how all workshop manuals I've seen have shown the process, including the one from Honda.  What manual are you using?

mystic_1

[MCRider]

The transmission countershaft, shift drum, and shift forks all go into the lower case but they won't fall out when you flip it over.

This is how all workshop manuals I've seen have shown the process, including the one from Honda.  What manual are you using?

mystic_1

That's right, my EVERYTHING could have been misinterpreted. I meant everything except what you said. 

[mystic_1]

I know that you knew that, but I'm sure you knew that already, you know? 

mystic_1

[MCRider]

I know that you knew that, but I'm sure you knew that already, you know? 

mystic_1

I know you knew i knew you know? 

[Hannibal Smith]

I assumed it was a 550 where the primary shaft is in the lower case, is the 750 primary shaft in the upper case?

I figured he would only ask that question if the primary shaft was in the lower case.....

Whaaaaaaa?

[mystic_1]

Mine is a 750, forgot to mention.

mystic_1

[jasonseasen]

Thanks everyone for your assistance. Sometimes newbs make silly mistakes. I understand now what needs to be done!

[Hannibal Smith]

Thanks everyone for your assistance. Sometimes newbs make silly mistakes. I understand now what needs to be done!

Hope you didn't take my advice!