Back in the mid 1970's, a friends 400 Suzuki had the same problem with splines on the output shaft. We bought a new sprocket and I tack welded the sprocket to the shaft being careful to limit heat around the seal. If that fix broke or the sprocket needed replaced he could then do the full tear down you have done. That worked for the several more years he owned that bike. He never did split the engine.
Honda do/did a special spline lube to take some of the shock out of the sprocket/spline. I use it on the early and late splines (and a new retaining plate each sprocket change) lots of chain play is a big help as well. Set it so its a wee bit slack at max suspension compression and thats about right imo.
Thanks Chuck. It’s definitely bit intimidating the first time you do it, but it’s really not that bad once you dig into it. Having a manual and taking lots of pictures helps too.
The gasket maker looks like Honda Bond or Yama Bond. You will want to use it in spots like case half’s valve cover. Regular RTV won’t last. Good video.
Hmm, I wonder if the previous person just loaded that up with rtv because it definitely wasn’t that little rubber bung that goes there now that you mention it. Good eye and thank you!!
the flywheel taper wasnt tight as you mentioned. run some valve grinding paste on the crank taper and lap it against the flywheel by spinning the flywheel on it without the key. just be sure to clean it off. this will make sure it stays tight and doesnt shear the key.
You've probably finished this job by now but: Is that homemade tool a precise enough fit on the special nuts? They look chewed. Are those J.I.S. screwdrivers you're using? Some of those crosshead case screws l would NOT be re-using. Generally good careful work, keep looking at the manual and watch out for the dowels. 👍
Still need to put her back together but that is a homemade tool. The nuts were a bit chewed up from someone else being in there. I am using JIS screwdrivers. Which case screws are you referring to? All of the case bolts holding it together along with the side covers are all 8mm bolts. The only screws I can think of at the moment are the two that hold the oil pump on. Thanks for the analysis! You always have a good eye for the detail 👍
@Garage2Trail Fair enough on points one and 2. Any cross heads that are chewed l would replace. That engine is in surprisingly good condition (given that it's an '83 with that filter/head/follower design). I don't think l would even replace the rings if they measure within tolerance. That minimal amount of 'blow by' could have occurred before the rings bedded in. Even the head and cam/followers look reasonable from what l could see on camera. Has the tensioner blade rubber gone hard?
Yeah I was surprised at how nice it was inside. I am going to replace the rings and piston pin and hone it. The rings were still barely in spec but on the far end. Figure I’d replace them now since it’s apart. I’m also replacing the cam chain and tensioners with OEM Honda stuff. The tensioners look a bit worn. Getting an OEM Honda head gasket and acorn nut crush washers for the cylinder too.
Back in the mid 1970's, a friends 400 Suzuki had the same problem with splines on the output shaft. We bought a new sprocket and I tack welded the sprocket to the shaft being careful to limit heat around the seal. If that fix broke or the sprocket needed replaced he could then do the full tear down you have done. That worked for the several more years he owned that bike. He never did split the engine.
Hey, if it works roll with it! Lol
Honda do/did a special spline lube to take some of the shock out of the sprocket/spline. I use it on the early and late splines (and a new retaining plate each sprocket change) lots of chain play is a big help as well. Set it so its a wee bit slack at max suspension compression and thats about right imo.
Thanks for the heads up!
Good job brother. Happy new year.
Thanks buddy, Happy New Year to you too!
Great video
Thanks!
This one fought you a little, but it is a great video. Very interesting. Opening up that transmission would be a little scary for me.
Thanks Chuck. It’s definitely bit intimidating the first time you do it, but it’s really not that bad once you dig into it. Having a manual and taking lots of pictures helps too.
Nice job! Very tutorial!
Thank you!
The gasket maker looks like Honda Bond or Yama Bond. You will want to use it in spots like case half’s valve cover. Regular RTV won’t last. Good video.
Thanks! I think it was Honda bond looking back at it
Great video m8
Thanks buddy!
14:34 that oil passage is meant to be plugged. thats a honda part you removed from there
Hmm, I wonder if the previous person just loaded that up with rtv because it definitely wasn’t that little rubber bung that goes there now that you mention it. Good eye and thank you!!
@Garage2Trail yeah likely. Does the same thing
Thanks again for pointing that out! Just ordered one
the flywheel taper wasnt tight as you mentioned. run some valve grinding paste on the crank taper and lap it against the flywheel by spinning the flywheel on it without the key. just be sure to clean it off. this will make sure it stays tight and doesnt shear the key.
Good idea!
You've probably finished this job by now but:
Is that homemade tool a precise enough fit on the special nuts? They look chewed.
Are those J.I.S. screwdrivers you're using?
Some of those crosshead case screws l would NOT be re-using.
Generally good careful work, keep looking at the manual and watch out for the dowels. 👍
Still need to put her back together but that is a homemade tool. The nuts were a bit chewed up from someone else being in there. I am using JIS screwdrivers. Which case screws are you referring to? All of the case bolts holding it together along with the side covers are all 8mm bolts. The only screws I can think of at the moment are the two that hold the oil pump on. Thanks for the analysis! You always have a good eye for the detail 👍
@Garage2Trail Fair enough on points one and 2. Any cross heads that are chewed l would replace.
That engine is in surprisingly good condition (given that it's an '83 with that filter/head/follower design).
I don't think l would even replace the rings if they measure within tolerance. That minimal amount of 'blow by' could have occurred before the rings bedded in.
Even the head and cam/followers look reasonable from what l could see on camera. Has the tensioner blade rubber gone hard?
Yeah I was surprised at how nice it was inside. I am going to replace the rings and piston pin and hone it. The rings were still barely in spec but on the far end. Figure I’d replace them now since it’s apart. I’m also replacing the cam chain and tensioners with OEM Honda stuff. The tensioners look a bit worn. Getting an OEM Honda head gasket and acorn nut crush washers for the cylinder too.
@Garage2Trail Wow, the rings have done sterling service then.
Sounds like you're on top of things. 👍
Here
If you like jigsaw puzzles just buy an old motorcycle engine and take it apart endless hours of fun
That’s how I look at it! Like a big mechanical puzzle.
@@Garage2Trail 🧩🧩🧩😀