engine rebuild

[MIKE550/4]

hi all

right after hours of tedious cleaning, scraping , priming, painting lacquering etc finally ready to rebuild this engine, have a compresor on way to replace stem seals... so engine rebuild

totally new to this and firstly must thank all on here been a great help ( extra thanks to bryan j , anything he does not know about these bikes?)

ok all surfaces to be mirror clean, can you guys give me tips on rebuild, few things i am confused with ie order to rebuild, scared about missing a gasket

confused about cylinder sleeves at base do these sit inside base gasket or around the barrell and pressed down

base and head gasket look the same? is base more paper?

tach drive gasket ... please explain in lamens terms

also position of pistons .. is there a set position

have included some pics ( apologies a bit blurry on a couple)

maybe usefull to some to show what you now get

cheers again  mike

ps 2 pics showing main gasket , but you also get the following

p91204286003  KICKSTART SHAFT
p01205283015  SPROCKET SEAL
p91202426003  NEUTRAL SWITCH
91256-096-651 TACH DRIVE
p91201323005  CRANKSHAFT GENERATOR END
p91201300003 CRANKSHAFT POINTS END
91259vm0000  CLUTCH OPERATING ARM
9120737h000  BLANKING PLUG
p91202kfl841  GEARCHANGE SHAFT

missing is the pucks ( as per bryan )6 x  91318-300-013

[SteveD CB500K0]

Got any better pics Mike? I've tried blowing them up to [width=600] which is best for this forum but they are too pixelated.

[MIKE550/4]

heres a link to full sized photos if that helps steve

[matthewmosse]

Head gaskett has 2 6 mil bolt holes sticking out in front of and rear of camchain tunnels and metal rings round piston holes plus is far heavyer duty to base gasketts, there are as I recall 4 X O rings lodged around the bottom of the cylinder liners in a groove between the liners and alloy casting. There is a seal inside of the tacko drive (inserty thingy) and an O ring on the outside.

[SteveD CB500K0]

If you paste the "IMG Code" from Photobucket into your post, you'll get the pictures direct.

I've edited your post to show.

[MIKE550/4]

cheers steve

would this be worth building it up back in the frame

ie put bottom end back in frame first ?

[SteveD CB500K0]

I don't see why not. You can do a complete top end strip on the 500/550 with the engine in the frame as there is enough clearance for the cylinder head below the main frame tube (unlike the 750).

[Bryanj]

Also means its not as heavy and easier to get into the frame without scratching the paint!

[MIKE550/4]

ok engine is in , did it lay on side method and put frame onto it, not too bad

anyway question straight away,been looking at microfiche and need to check something which looks important, i seem to be missing whats called a dowel pin

2 sit on the barrels, not sure if diagnol or same side but sure i should have 2

if i am missing this are they still available, or anyone got one

think its part no 94301-12180 or 94301-12160

cheers all

mike

getting there slowly 

[Bryanj]

Do you mean cylinder to head or cylinder to crankcase?

[MIKE550/4]

cylinder to head ,have none to the crankcase 

[MIKE550/4]

hi all

cannot get the cam to sit correctly,feeding it in from the right , seems the cam chain keps getting wedged, any tips

2 questions on fitting the cam cover, realise i have to set cam and mark in timing window my book has big oily print on it and not very clear, is it notch level with cylinder head joint face? and line in between t and f markings in the middle of window at bottom?

also noticed fitting cam cover on the cylinder head can cause problems ( bent valves?) so whats the process to avoid this




cheers

mike

[Bryanj]

Mike use this link:-

http://forums.sohc4.net/index.php?topic=369.msg57914#msg57914


And i will try and call tonight

[MIKE550/4]

i am doing some thing wrong tried all afternoon with no joy  , seems realy tight, can get one side on, but will not go over the top, gave up now before i break the chain, will await your input