Honda-SOHC

I'm a bit confused (easily achievable). Have you not just stripped and rebuilt the engine? Did you fully clean the sump pan by removing oil separation plate? If it's the wrong sump bolt, which makes sense as there shouldn't be a dowty washer there anyway, did you not notice any damage / repair / bodge around the area?

Haha of course I noticed it. But pay attention, and check against other engines? No.  The sump has had a repair, it's been welded and I did a small amount of smoothing before I sent it off for cleaning. But the threads looked good and I assumed it wasn't leaking, as there wasn't a pool of oil on the garage floor before I took it all apart.

The bolt I have is about a 22mm (from memory) head, the thread looks to be about 15mm (I measured this so I could get a copper washer that might fit from the local fastenings place).

Bottom line is that I will have to get an unbuggered sump for the girl when I can prove it runs.

Is there a variation in oil drain bolt sizes?

Bought a washer online described for F0/77, took out leaky dowty style washer, plugged hole with finger, struggled to get old washer off plug one-handed, eventually 7 year old mini-me helped, but then realised the new washer I have is way too small to go on. Reassembled and washed (thankfully unsullied) oil off my hands and scratched head.

Mine is an early engine. I can only think the bolt sizes changed, or someone has already mullered my sump and it's a bigger bolt in there.

Small amount of progress, but momentum is building now...

Chain on. Adjusted the rear wheel. Chain guard on. Sprocket cover on. Gear lever on. Now can confirm the electrics seem to work, in that I have oil pressure and neutral lights. Horn was refurbed but now refuses to work. Most likely because of my awful attempt at re-crimping it. Think I'll have to admit defeat and buy a new one

Tank is currently outside as it's dripping occasionally. I had 2 tanks and took the best looking petcock and put in the better tank after cleaning with Phosphoric acid. I opened up the other petcock and can see some O rings that are probably the culprits of the leaks. Will see if I can get replacements.

Spent a while puzzling over the breather tube. There's a long pipe that goes from the collector under the air filter up to the top of the cam cover, but I can't work out how the air plenum connects to it, should there be a tee piece?

Seems like another lifetime ago this was in one piece. Happy (!) to report it is possible to get an engine in with just one person. Laid the engine on a mat, propped it up at a bit of an angle and then laid the bike over the top of it. Bit of shoving and humping around and then lifted the both of them together.

At that point I realised the good old powder coating issue. Rear bottom engine mounts are so tight, they won't accept the engine with the powder coat on. So, while on the main stand, with the front lowers in I jacked the engine up and chiseled the coat off around the insides. Slather with grease and try again - job is a very goodun'.

Sheepishly looking forward to it now! Thank you!

It's tight but not adjusted. I think start and break-in will be ok with it as is, what you reckon?

I saw some people had issues with this, but I fitted mine last week and it stayed in the groove just fine. Could be because it was completely dry maybe?