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Author Topic: Lets build a SOHC for less than a grand  (Read 24916 times)

Offline Oggie400F

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Re: Lets build a SOHC for less than a grand
« Reply #150 on: January 27, 2020, 12:57:01 PM »
Thanks for that. I’ll get a new spring and longer adjusting screw on order.
Are these just BZP?
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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #151 on: January 27, 2020, 02:16:26 PM »
Quote from: Oggie400F on January 27, 2020, 12:57:01 PM
Thanks for that. I’ll get a new spring and longer adjusting screw on order.
Are these just BZP?

BZP machine screw and a stainless spring  ;)
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Offline Johnwebley

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Re: Lets build a SOHC for less than a grand
« Reply #152 on: January 27, 2020, 08:35:45 PM »
I found the mounting lugs on the RH leg needed "finishing".


  several assemblies ,and checking ,them filing to get the caliper parallel,and ensure the arm will swivel freely.


  the better the alignment,the less spongy the brake will be untill it full beds in .
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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #153 on: January 27, 2020, 10:11:58 PM »
Quote from: Johnwebley on January 27, 2020, 08:35:45 PM
I found the mounting lugs on the RH leg needed "finishing".


  several assemblies ,and checking ,them filing to get the caliper parallel,and ensure the arm will swivel freely.


  the better the alignment,the less spongy the brake will be untill it full beds in .

Cheers John  ;) that is what my findings are. Take a some off the fork leg mounts or take some off the pivot arm mounting points.
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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #154 on: February 01, 2020, 08:40:35 PM »
Did a quick re bore to 0.50 and painted the top end. To prepare pistons, make sure there are on little burrs that have been missed and if any found just take a very fine file to remove them.
Rebore on these pistons which are silicon alloy, and the piston to bore clearance 0.0250mm with a fine cross hatch. pistons matched to the bores.

Fit the CW15 circlip/ring clip. Piston 1&2 on the right side, 3&4 on the left. A smear of grease on the gudgeon pin and make sure it moves freely in the piston. Top ring usually has a chrome finish to the edge and numbers or letters face up. Second ring is usually black and numbers or letters face up. The best oil rings come in three parts and have no markings.

A smear of grease on the small end of the con rods and ready to fit to the rods. Arrow or triangles face the front, second circlip in
Prepare the bores with a smear of Graphogen on the bores, rubber grease on the outsides makes fitting the silicone 0'rings much easier.


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« Last Edit: February 02, 2020, 11:51:26 PM by Trigger »
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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #155 on: February 01, 2020, 10:24:34 PM »
Barrels going back on, cam chain guide in and drop the barrels down. For some reason the barrels will not seat on the right hand oil jet and the left hand oil jet seated too easy. Barrels back off and I have a problem.
When I stripped this engine down, I was in a rush and had not noticed that the left side oil jet had been broken off in the barrel and drilled, also the right side had been drilled out so the oil jet could be fitted upside down  :o  I can't believe that I have had these barrels acid cleaned, peened, painted, rebored and it is not until I have come to fit them, I have noticed a problem  ::)

Time to walk away and go back to it another day  :'(


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« Last Edit: February 01, 2020, 10:28:47 PM by Trigger »
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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #156 on: February 02, 2020, 12:04:40 PM »
After a good sleep and a clear head.
Drilled out, reamed until I had a nice clean hole to work with and made some sleeves up for a press fit and a 9mm ID for the oil jet to sit in  ;)
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Offline Bryanj

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Re: Lets build a SOHC for less than a grand
« Reply #157 on: February 02, 2020, 12:37:19 PM »
Knew you waz a decent engine driver mate!!
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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #158 on: February 02, 2020, 11:37:21 PM »
After my little repair to the barrels it is time for some head work.
Re grind the valve seats to Honda spec which is 37.5, a 45 and a 63.5 degree. Re face the valves with a 44.5 degree.
With valves and seats at a near match, just a little lap in with very fine grinding paste to get the perfect valve to seat match.
A smear of silicone grease on the valve stems and valve guides that were well within spec. Valve seating washers, valve stem seals and the springs back on with collects seated.

Locate the front cam guide and insert the tensioner and set it, head gasket on with upgraded 0'rings ( the only 0'rings I ever use from a full gasket seat are the silicone liner rings)

Head on and torque down to 18ftlb and will leave it as it is and re torque it again tomorrow  ;)   


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« Last Edit: February 02, 2020, 11:55:49 PM by Trigger »
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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #159 on: February 02, 2020, 11:43:43 PM »
A valve face doesn't need to be ground to death, you only need a 1 to 1.4mm face on them  ;)

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« Last Edit: February 02, 2020, 11:46:08 PM by Trigger »
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Offline 10tenmen

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Re: Lets build a SOHC for less than a grand
« Reply #160 on: February 03, 2020, 09:33:43 AM »
Trigger I am in awe of your craftsmanship it’s a joy to see and read, can’t wait to see the finished article.
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Offline Erny

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Re: Lets build a SOHC for less than a grand
« Reply #161 on: February 03, 2020, 11:42:37 AM »
Trig, with regards to second rotor/caliper, do you know this article? Maybe you can find some inspiration there?
https://blacksquaremotorcycle.com/dual-disc-conversion/

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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #162 on: February 03, 2020, 03:09:44 PM »
Quote from: Erny on February 03, 2020, 11:42:37 AM
Trig, with regards to second rotor/caliper, do you know this article? Maybe you can find some inspiration there?
https://blacksquaremotorcycle.com/dual-disc-conversion/

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Yes, I have read the link but, they are taking about the bike they are working on, there are many different types of fork legs   ;)
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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #163 on: February 03, 2020, 10:31:34 PM »
Re torqued the head down and now time for the cam and rocker cover to go on.
Set the timing mark to 1.4, a smear of graphogen on the cam journals, cam shaft in from the left side with the cog on and line up the notch with the top surface of the head and the notch facing the front. Lift the chain on to the cog and locate the cog on the shaft. Have the sprocket bolts nice and clean, a dab of stud lock on the threads and torque to 12ftlb.

Rotate the crank 360 degrees and make sure the timing marks all line up. Turn the crank a little past the 1.4 mark to were the spring is mounted. This is the best position to set the cam chain. Tighten up the top bolt on the tensioner and loosen the nut on the at the bottom and it will automatically tension itself, hold the screw in place with a screwdriver and lock it using the nut.

Coat the cam lobes with a dab of bearing guard. Some people will tell you that you just put the pucks/ head sealing rubbers but, I always smear Honda bond on underside of the lip.

Prepare the rocker cover and take back the tappets and hold them up with elastic bands and a new gasket lightly smeared with silicone grease and bolt it down starting with the 4 bolts under the breather cover and work out a couple of turns at a time. Once bolted down put the breather cover on with a new gasket and a smear of silicone.

In my early years I always had trouble setting tappets, my teacher explained that you need 3 feeler gauges. If you are setting the inlets to 0.05 and it is just dragging, try to put 0.08 in, if 0.08 goes in then it is too loose. The same with the exhaust clearance, if you are setting to 0.08 and you can get 0.10 in it is too loose.

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« Last Edit: February 03, 2020, 10:35:53 PM by Trigger »
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Offline Trigger

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Re: Lets build a SOHC for less than a grand
« Reply #164 on: February 03, 2020, 10:39:03 PM »
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« Last Edit: February 03, 2020, 10:41:22 PM by Trigger »
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