Sunday, June 3, 2018

Red: Bottom End Transplant

Epic day on the carpet to transplant the engine from the 495-507 Trochoid case (will no bill of sale) to the new 482-234 case from Bill (with bill of sale).

Work notes are in Volume 3, page 22.  Also captured this in procedural notes.

Just random highlights:

  • Had been especially worried about fitment of the crankshaft, but it went it pretty easily just using a gentle "rocking" motion.
  • Testing the oil pump and found the gears were very gravelly and would barely turn.  Then realized that it was missing its gasket.  With that installed, it turned perfectly.
  • Used the heat gun to install new Nachi bearings on both sides of the case.  Although later during re-assembly, realized that the small bearing could be installed just by hand and would fall out pretty easily.  
  • Added in a "Nippo" brand crankcase gasket (made in Vietnam).  Had a couple unopened Honda NOS gasket sets, but was wondering how much the material degrades over time.
  • Had an issue once the cases were together where tightening the bottom or left side screws caused the mainshaft to lock up.  Took the whole thing apart and with these two things fixed, was able to get it closed and working.
    • Make sure to turn the shift drum fully counterclockwise before closing the case
    • Also make sure the kicker is in the "unlocked" position 
  • Had to remove one knock pin from the Right Cover where the case already had one.  Ideally, I think you want both the knock pins on the case so that you can hang the gasket off it, but having one pin on each seemed to work fine.























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