Honda-SOHC

As it was missing on my 500 I am fitting the chain guard that bolts inside the left side chain case cover.

Two M6 bolts hold the protector in place, one has a spring washer, the other has a tongued washer part number 90532-323-000. that is  shown as no longer available.

Is it okay to use a spring washer instead or is the tongued washer an essential locking tab?

Do I need to fabricate a lock washer for this location?

.left-crankcase-cover_bigma000082e11_91d1 by Macabe Thiele, on Flickr

When I removed the front pipes on my 500 three of the studs came out with the nuts.- so in an ideal world I would like to replace them with new SS studs.
On examining the remaining five studs I suspect they are not original as they are fully threaded with no unthreaded section.
I have tentatively tried  using the two nuts method to remove one but it has not worked as the nuts just moved up the threads despite being very tight. I am wary of stripping the threads to compound the issue.

Is there a better method of removing them as I do not fancy breaking/or stripping a stud by being cack-handed.

I have a plumbers gas blow torch as a heat source if this might help?

It is possible I misplaced a part but should there be a thrust washer or shim between the clutch outer basket and the gearbox bearing ?

Is there a previous post covering the correct assembly order  of the clutch operating mechanism thus working out what size shim is needed. I have done some trawling with no joy - lots of posts on various issues but no definitive advice found on best practice.

Thanks in advance.

Just had an e-mail from Autocar as I share a subscription with my best mate - they have started putting old digital copies on their site that I think you can order - my access is free for a week.

Be great if Bike Magazines do/did the same thing.

A random screen shot from 1973 issue  if it works is shown below - it's not very clear text from a screenshot but you get the drift - extra to download or order the magazine..

,Screenshot 2023-07-21 121239 by Macabe Thiele, on Flickr

At some point I need to shine up the left side alternator cover/housing - clearly makes sense to remove the alternator stator for the polishing job - only one screw has come out so far.

Presently soaking stuff with penetrating oil - might need to get my young friend Marco to see if he can shift them - he talks about cutting a cross with his Dremel tool the using a screw driver that you can put a spanner on.

The three inner JIS heads have had some straight impact with a big Honda T Bar - that shifted one - drilling out does not look like an option as the screw shaft  is not accessible. Outer three might be okay to drill the heads out as a last resort.

Is there a way that works in my limited tool workshop?

.alternator housing by Macabe Thiele, on Flickr

If it was just the contact tip I could potentially solder in a new contact - mine has been cut back in the past  & bent to make contact.

Part number is 35752-323-000 Stator none at CSML - tried a few places - no joy.

Anyone have one to spare either good complete or that just needs the tip replacing?

Thanks Ted

A bit of an update about the two powder coater I have used locally.

1. For my 400 I used Langley Powder Coater - so far no issues with my frame after 2 years - the coating was a tad thicker than I would have liked but at the price the finish was excellent. Done during Covid -  cost £155.

2. For my 500 I used RPT Engineering near Alfreton - the finish was excellent at the time being nothing like as thick as on my 400.  cost £190.
Sadly the underside of the rear of the frame now has some corrosion breaking through - my plan atm is to apply some black Hammarite as the area is well hidden but I will know it is there.

Why did I change - primarily due to price as Langley Coater wanted me to get the frame specially dipped elsewhere before they would touch it as it had been previously coated 20 years or so ago.  Total cost was estimated at around £350 in total.

Just been looking up the torque values for the 8mm & 6 mm crank case bolts for my 500.

Could be lost in translation/conversion - it seems that they changed  the values down wards for the 8mm bolts & upwards for the 6mm ones between the 400/500 engines?