Engine teardown and inspection

[cantarauk]

Most of the components required for the engine assemble have arrived so I will be making a start at building the motor. Since this is the first time I have undertaken such a task I will be taking it slow documenting everything.

The engine cases have been cleaned and sprayed and baked

[cantarauk]

There seem to be different ways to do this but I have opted to start with the top half of the case seated on a homemade made frame to keep it steady.

Gear shift and drum inserted first with each part well lubricated with assembly lube.



Looking at the top half of the case with the crackshaft to be positioned at the top. Drum lubricated and inserted from the left side of the case with the left gear shift fork assembled with the pin and circlip side facing the left.



Next gear shift fork B assembled with the pin hole and circlip side facing the right hand side of case.



The right gear shift fork assembled again with the pin hole and circlip facing the right



New oil seal inserted and the drum pushed completely in

[Nurse Julie]

Great work.

[cantarauk]

Starter gear and shaft cleaned lubricated and installed with the M6 retaining hex bolt torqued down to 1.0 Kg-Meter

[K2-K6]

Nice work cantarauk, also one of the most enjoyable parts of rebuild after all the cleaning etc.

[cantarauk]

Conrods cleaned with new shell bearings that were measured to match the crankshaft specifications. 



Crankshaft was sent off to machine shop to be measure and balanced. New crankcase shells that were matched to the work the machine shop did in meeting the required specifications. Crankshaft cleaned and then greased well before returned to me.




To the left on the image new Cam Chain and Primary chain




New shells about to go in

[cantarauk]

Thank you K2-K6. Taking my time as loads of reading to do to be sure I don't screw anything up

[McCabe-Thiele (Ted)]

All looks nice and clean.

[cantarauk]

New shells inserted fully



Camchain and Primary Chain fed onto the Crankshaft and in position with the crankshaft dropped into the top case



Oil seals for both sides of the crankshaft





Conrods connected, bolted up and nuts torqued down to 2.0 Kg-Meter




Top view of it all nice and snug in the case

[Trigger]

Not sure what you have on the back of the shells but, they should be dry to the case and rods 

[Skoti]

Nice job and great photos,

I've never seen the crank journals greased up like that before assembly, is that standard practice?

I normally just oil them lightly.


Good luck with the rebuild

Skoti.

[cantarauk]

Tigger metal on metal got it. Will clean and re-seat the shells

Skoti - Cheers. The crank and conrods both came back like that from the machine shop covered in grease and to be honest I too quiet a bit off before connecting up and dropping in.

This is what it came back like - Crankshaft was covered thicker

[philward]

Nice job and great photos,

I've never seen the crank journals greased up like that before assembly, is that standard practice?

I normally just oil them lightly.


Good luck with the rebuild

Skoti.

Most of the experts on here recommend using Grafogen (proberly spelt wrong!) as an assembly grease - to ensure pre oil pressure lubrication of metal to metal surfaces such as big ends, mains, cam journals, etc.

[cantarauk]

Need three things checking please as I hope some of these are correct but could do with a Jedi/Expert opinion to validate.

For the Countershaft assembly No 19 and No 20 on the image is the way I put these washer back correct



The way I put these back below but I am more interest in washer 20 to see if the turned pieces went in the correct way. No 19 I assumed is the flat washer and No No 20 the washer that has bent ears for the I/D piece.






The second thing I need checking is with the Mainshaft when I stripped it down there were 2 washers where No 18 is.



I started putting this back without the second washer. Below is what I found when I stripped the Main shaft down for cleaning.





The 3rd query is reading the Haynes manual when inserting the second drive it says - " Ensure that a new oil seal has been fitted to the secondary drive sprocket end of the layshaft and that a new O ring positioned behind the oil spacer" From the parts images above I can't see this O ring only the one that fits between the bearing and the fixed positioner on the mainshaft No 3.

page where I read this added below -



I did not remove the bearing No 22 all the way to No 7 only No 19 to No 24 for cleaning. So assume O ring No 27 is still there
 

[Skoti]

Nice job and great photos,

I've never seen the crank journals greased up like that before assembly, is that standard practice?

I normally just oil them lightly.


Good luck with the rebuild

Skoti.

Most of the experts on here recommend using Grafogen (proberly spelt wrong!) as an assembly grease - to ensure pre oil pressure lubrication of metal to metal surfaces such as big ends, mains, cam journals, etc.



Phil,

thanks for the Graphogen tip, it's something we never used or had in the seventies when I worked in a Honda franchise. Although I remember using something similar during the eighties in the motor trade whilst renewing MK1 Astra camshafts.

As ever I'm always learning new stuff from the posts and fantastic photo documented rebuilds on this website.

Regards

Skoti