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 Post subject: Wifes Engine CSI
PostPosted: Fri Nov 26, 2004 5:59 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Remember this? viewtopic.php?t=700

I started taking the wifes Engine apart today so I can install a rebuild crank
(new Honda OEM rod assembly ) and new crank bearings.

I sent Lee some other failed crank bearings for inspection he said something about
lack of lubrication, I found plenty of oil in the bottom end of this one, perhaps there is
plenty in the bottom its just not getting to the bearings?

Red arrow is pointing to the oil that was in the bottom of the crank case and stuck to
the lobe of the crank as I rotated it, the blue arrow is one of the path ways for the
bearing to get oil, more on this later...


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 Post subject:
PostPosted: Fri Nov 26, 2004 6:04 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Here is a close up of the oil hole during a bottom end rebuild I usually chamfer
this hole so any oil that falls out of suspension can drain into the hole, I also
elongate the hole to increase volume.


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cranklube1.jpg
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 Post subject:
PostPosted: Fri Nov 26, 2004 6:07 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Here is the flywheel puller you need to properly pull the Pilot flywheel without doing
damage to it, I included the part number. 07KMC-HEo0100
07KMC-HE00100 ROTOR PULLER
http://www.partzilla.com/parts/detail/h ... oCdnrw_wcB
Pilot flywheel puller


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 Post subject:
PostPosted: Fri Nov 26, 2004 6:09 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Nice and clean inside the stator case, the black gasket material is a indication those are
the factory gaskets..


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 Post subject:
PostPosted: Fri Nov 26, 2004 6:11 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Here is the socket you need to remove the big nut that holds the balancer drive
gear on the crankshaft, the threads are LEFT HAND!!!


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 Post subject:
PostPosted: Fri Nov 26, 2004 6:16 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Here is the crank case of a Rotax 440 sled Engine notice the groove in the casting (blue
arrow) looks like the oil that falls out of suspension gets trapped here then is channeled
to the hole (green arrow) where it feeds the crank bearings.


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 Post subject:
PostPosted: Fri Nov 26, 2004 6:19 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
I think what I will do is grind material off the cases above the black line to create a trough
where the black line is then all the oil that falls out of suspension when the Engine is running
will be guided down to the bearings, when the Engine is off any oil from the walls of the
transfer ports can drain back down also.


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 Post subject:
PostPosted: Mon Nov 29, 2004 7:39 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Hoser, by grooving that will that hurt the case at all, will it provide a point for weakness by chance?


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 Post subject:
PostPosted: Mon Nov 29, 2004 8:38 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Mudbogger wrote:
Hoser, by grooving that will that hurt the case at all, will it provide a point for weakness by chance?


I don't think so, I didnt remove much material (pics later) there is not much material
there to remove! I think the best way would be to build up below the line with some
epoxy like the devcon stuff, I don't trust JB enough to put it there, I don't have any
of the devcon handy!


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 Post subject:
PostPosted: Tue Nov 30, 2004 12:21 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Ok here are some pics


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 Post subject:
PostPosted: Tue Nov 30, 2004 12:29 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Getting back to the engines autopsy removing the crank from the left crank case
revealed the clutch side crank seal was pushed in to far and also was crooked, in
the picture you can see the uneven wear in the the rubber seal (green vs blue arrow)
you also can see on the bearing where it was rubbing the inner race of the bearing, the
rubber then got into the bearing and caused it to fail? At one time in the past this Engine
sucked a cylinder gasket on the clutch side http://pilotodyssey.com/cylindergasket1.htm
the sand and dirt took out the bearing?


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 Post subject:
PostPosted: Tue Nov 30, 2004 12:30 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Where it was rubbing the bearing inner race.



So how did the seal get pushed in to far (crooked) on one side, I have had rocks
and sticks end up between the brake disc and the trans case and between the
axle and lower control arms perhaps one got between the back of the drive clutch
and the crank seal? Shredded drive belt at one time? I don't recall shredding one
on this Pilot... Always something hah


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