Engine teardown and inspection

[cantarauk]

With the new parts that arrived and over the Xmas period to escape the insanity of been cooped up I braved the cold in the  garage to get some more work done.

Mainshaft assembly

All parts cleaned and checked 


Before the first gear goes on the shaft there should be a circlip against the bearing. Note - Circlips are Honda specific which are flat one side and rounded/curved the other and shaped as show below.


Forth gear then gets pushed against the bearing flat side first.


Next the thurst washer and circlip to hold the gear in place


2nd and third mainshaft gear


mainshaft top gear


thrust washer


roller bearing and then all painted with some assembly lube


Drop the mainshaft into the top case aligning the middle gear shifter fork to sit between second and third gear. Align pin with the roller bearing and give a spin.

[cantarauk]

Countrshaft cleaned and checked ready for assembly


replacement countershaft


Tope gear and circlip




Thrust washer and second gear




Thurst washer and lock washer which now fit since another replacement gear received


Third gear thrust washer and circlip





Forth gear


Lower gear with bush inserted with the flange side sitting against the forth gear


Needle bearing to top it off


Drop the countershaft in aligning the outer gear shifter forks to be positioned on forth and top gears

[SteveD CB500K0]

The people who designed these (without computers) have my admiration.


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[Bryanj]

As people used to say "Runs like a Swiss watch"

[Bryanj]

I'm sure there is a bulletin on the US site about circlips but talking about 750

[cantarauk]

Thanks Oddjob - Have amended to add this sound advice

[cantarauk]

Parts cleaned and ready for assembly


Shaft through bottom half of case with spring and circlip


gear



Thrust washer and large spring






Kick starter ratchet and thrust washer then small spring




Ratchet guide plate on next and push on on to compress the spring. As you looking at the ratchet from above the arm of the ratchet guide need to point down and will lock into the case. A not tricky but will have to keep it there with one hand while doing the rest.


Finally add the washer and then attach the circlip to hold it all in.

[Bryanj]

Hopfully i have attached a Honda buttetin and it dont throw your work out the window mate

[cantarauk]

Thanks Bryan.

I have some very closeup photos so will check all circlips but from memory think they I were all assembled as per the service bulletin


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[taysidedragon]

😁Just a translation issue. They probably swear at the English language and words that sound the same with different spellings or same word meaning different things.
It sure confuses the hell out of the USA! 🙃

[cantarauk]

Speaking of translation and presentation could someone please explain this to me so I know what is needed. For the clutch components No 12 is a spacer shown below.



But then how do I know what spacer I require for a 500K1 bike ?



I get the remarks with the greater and lower than the engine serials but how does one know what thickness ?

[AshimotoK0]

You need to choose the correct thickness to give the correct clearance, as detailed in the Shop Manual.


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[Bryanj]

Thicknessess of plates are all the same and in the manual and the different part number is square friction pieces not angular. the shims are not easy to get and you work out total play with no shim and a dti take off the clearance and fit shims to the resulting size, unless you are fitting new parts using the old one works

[cantarauk]

Thanks both.