Author Topic: Magpie/Cliff's K0 Project (Read 82793 times)

Industrial Cafe · « **Reply #225 on:** February 06, 2011, 07:13:02 am »

hey Cliff,
it's really lookin' good.
cant wait to see the finished product.

Magpie · « **Reply #226 on:** February 06, 2011, 09:32:42 am »

Thanks guys! While on pause I have been able to assist a couple of young guys here with their builds - which I'm really enjoying. It's easy for me to help them spend their money and they welcome the help.
Cheers, Cliff.

Magpie · « **Reply #227 on:** February 06, 2011, 03:36:36 pm »

Maybe I can play a bit still - with the original engine my bike came with. It's got all the fins intact, looks good under the cam cover and had a leak down test. My mechanic friend that did it said it's a good motor. It has been repaired for a chain break and looks good in there. But, it needs a good cleaning and repaint, so I'll take it apart. I have a set of primary chains and tensioner, the cam chain tensioner and good engine covers. I can lap the valves in and consider a hone job and new standard sized rings. Just to keep me busy. Besides it will make a good display motor or will go in the K0 frame if I come across a low numbered frame for the sandcast motor in the bike now.

Cheers,
Cliff.

Magpie · « **Reply #228 on:** March 10, 2011, 08:40:01 pm »

Got started on the tear down, removed the oil pan and found a surprise - looks like left over Hondabond. I was able to measure the play in the primary chains and they were well within spec. This engine has had a repair to the cases in the primary sprocket area so it's been apart before. When that was done they did a crappy paint job. The head was easy to remove much to my surprise. I'll strip it and take into a local shop that will plane it and jet clean it. I think I'll see if they can clean the cylinders too. Both the chain tensioners are toast. Apparently if you take the pistons out of the cylinders you should replace the rings so I may as well have the bores honed now too.
It's a start.
Cliff.

seaweb11 · « **Reply #229 on:** March 10, 2011, 09:01:34 pm »

Good to see you hard at it Cliff

Magpie · « **Reply #230 on:** March 12, 2011, 09:47:27 pm »

Got the motor torn down to almost empty cases. It was quite clean inside without much gunk or rust. I think it's a low mileage motor or was torn down before. It had allen head screws everywhere so it had to be out of the frame at least once. tThe cases are damaged at the primary sprocket seal area which I've posted a thread asking advice on what to do to fix it. I organized all the bits on my bench and now I can start to clean everything. The pistons and cylinders look good but the oil rings are the old one piece rings. I've been told I should put new rings in since I've got the pistons out of the bores.
Some pics:

MasterChief750 · « **Reply #231 on:** March 13, 2011, 06:04:28 pm »

looks likes it lost a chain at some point any holes/marks forward of the sprocket area?

Magpie · « **Reply #232 on:** March 13, 2011, 09:45:38 pm »

No holes but some machining marks. I'll have to look at another motor to see if that's from manufacturing or a chain problem. I'm beginning to think 754's thoughts may be closer to what's going on - someone hit the area with a punch to stop the seal from coming out or turning. They made a mess of it though. I've cleaned it up a bit with a dremel and will use some HondaBond on the seal when I assemble the motor. Cliff.

Magpie · « **Reply #233 on:** March 14, 2011, 11:53:29 pm »

Took the valves out of the head and will take it and the cylinders down to the local machine shop for a jet cleaning. They do a great job, it's like a giant dishwasher. I'll have them check to be sure the head isn't warped and see if the valves can be lapped it. The exhaust valve seats look like they may need more than just a good lapping though. You'll notice the K0 has valve guide seals only on the intake valves. Maybe that's part of the reason the exhaust ports look so crappy.
I have a thread about reusing the old piston rings but notice they are the one piece oil ring which may also help make this mess. I never had this motor running.
There's a broken off screw that I'll have to get out some how too. It's the top one for the primary sprocket cover. It's broken just inside the case and the po has hacked away at it and made a mess. I could try to drill it out and then Hellicoil it I suppose. The trick will be drill it out in the same spot. Just in my little efforts the drill likes to eat the aluminium of the cases and not the screw.
And, clean, clean, clean.
Cliff.

markb · « **Reply #234 on:** March 15, 2011, 06:04:43 am »

I've had to resort to having some broken off screws removed by using EDM (electrical discharge machining) when they were below flush. They use an electrode that's the same diameter as the minor diameter of the screw. It accomplishes the same thing as drilling them out in that you still have to pick out what's left of the screw threads but you don't have problems with the drill walking off center and damaging the threads. Good luck.
Mark

Magpie · « **Reply #235 on:** March 21, 2011, 04:07:33 pm »

Got the head and cylinders back from the machine shop today. They are both flat and true so no machining to do. The shop did a great job cleaning them. Now to lap in the valves.
Cliff.

markb · « **Reply #236 on:** March 22, 2011, 04:38:01 am »

Wow, they look great. What did they do to clean them?
Mark

Magpie · « **Reply #237 on:** March 22, 2011, 07:49:41 am »

They called it a jet clean, like a giant dishwasher. They use a cleaning agent called Turbodec (spelling?) in the machine and he bead cleaned the ports first.
Cliff.

Magpie · « **Reply #238 on:** March 24, 2011, 01:34:59 pm »

So, after reviewing the answers to my question about valve lapping I went at it this morning. ( http://forums.sohc4.net/index.php?topic=85684.msg969229#msg969229 ) Carefully went at it and I think it turned out ok. I lapped and checked, lapped and checked - less seems more doing this. The valves looked good to my untrained eye. Odiewan suggested assembling the head and putting diesel oil in the ports to check for leaks - so I'll do that next. Another milestone reached, I actually lapped my valves. Not sure I should admit to that, it sounds a bit like self abuse.

I still have to do a bit more cleaning of the exhaust ports too.
Cliff.

Magpie · « **Reply #239 on:** March 24, 2011, 11:20:21 pm »

I installed all the valves in the head without the valve guide seals to do the test recommended with the diesel oil to see if they leak. Tested each one and didn't see any sign of oil getting past the valves. Yahoo! Hopefully I did it the right way. I set the head on it's edge and filled the port with diesel and waited a few minutes. Nothing showed so on to the the next one. Since they all were good, I removed the intake valves and installed the valve guide seals. The K0 motors just have seal on the intake guides.
There was silver paint on the little noise suppressors between the fins so I cleaned those up too, as well as those on the cylinders.
Next I cleaned the cam chain tensioner then attacked the clutch pack. Each metal disk in the pack had rust on the tabs so I used a green scrubbie and lots of varsol and diesel to get rid of that.
All in all a good, satisfying night.
Cliff.

Magpie · « **Reply #240 on:** March 25, 2011, 07:12:36 pm »

More cleaning today, got the bottom case scrubbed and almost ready for paint. Wire brushed a bunch of fasteners to prep for plating too. Called to dinner by Simon the wonder dog. Cliff.

Retro Rocket · « **Reply #241 on:** March 26, 2011, 03:50:23 am »

Holy #$%* Cliff, you've built a dog.....

Magpie · « **Reply #242 on:** March 26, 2011, 12:22:30 pm »

Rats, someone beat me to it!

Magpie · « **Reply #243 on:** March 30, 2011, 06:58:01 pm »

Got a problem out of the way today. Someone, not me, had broken off the upper screw for the sprocket cover and then made a mess of it. It looks like they use a chisel across it and then dug at it with something. A friend offered to help so we carefully drilled a hole in the screw with the aid of another sprocket cover as a guide thinking we could use a screw extractor to get the offending piece out of the hole. No luck, the screw wouldn't budge so we drilled a larger hole for a larger extractor and it still wouldn't budge. We eventually had the hole looking like it was about 6 mm so I grabbed a 6 mm tap and preceeded to carefully cut some new threads in the hole and IT WORKED. Now I can clean up the upper case, paint it and get it ready for assembly. I got a gasket and seal set off ebay last night so i can asseble the bottom end at least.
Cliff.
Before and after shots. The hole still looks like hell and needs some more TLC but at least the threads hold a screw.

Magpie · « **Reply #244 on:** March 31, 2011, 09:25:41 pm »

A bit more done today: Cleaned the top case inside and outside in prep for paint but it will have to warm up a bit here before I can do that, took the oil pump apart for a good cleaning, the rotors (?) in the pump had some strange score marks so I took some out of a spare I had that were in better condition and finally got tired of moving stuff around on the bench so I could work on other stuff so I set up a table and laid out some of the major parts on it. Looks much better now!

Pretty boring stuff now, just cleaning and prep for the assembly. gaskets and seal kit coming in the mail.
Cliff.

ekpent · « **Reply #245 on:** April 01, 2011, 07:48:49 am »

I like the Pink-sure is PURDY

Magpie · « **Reply #246 on:** April 01, 2011, 08:34:13 am »

My feminine side is showing again - dammit.

Cliff.

Magpie · « **Reply #247 on:** April 10, 2011, 11:26:35 am »

A little more done last night, nothing on TV, a cold beer in the fridge, the wife's gone to bed so out to the garage. I got the cases ready for paint with some carboard and painter's tape.
Seems hardly worth posting but this is a great way to save this stuff.
Cliff

Magpie · « **Reply #248 on:** April 10, 2011, 11:29:27 am »

I cleaned up the oil pan that came on this K0 motor and it's been polished. I don't think that's stock and who would polish an oil pan anyway, you have to get on your knees to see it. On the other hand, I've seen people on their knees around the bike at shows looking to see where a wire goes or how something is placed on the bike. Maybe I should use it!
Cliff.

Magpie · « **Reply #249 on:** April 22, 2011, 04:38:25 pm »

A beautiful day in paradise so I set up my spray booth and painted my cases and the left handlebar switch. The paint looks a little heavy on the switch. I see what it looks like with the orange paint on it. I've left them in the sun to cure a bit. I usually get impatient about now so it's hard not to start taking the tape off. I also taped the little rubber noise suppressors in the cylinders and head. It drives me crazy to see those painted - anal I am. I'll get some paint on the head and cylinders later today maybe. The cad plating on the fasters came out nice so I can now assemble the bottom end. My foreman seems to approve although the sun made him a bit sleepy.
Slowly, slowly.
Cliff.

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Author Topic: Magpie/Cliff's K0 Project (Read 82793 times)