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PostPosted: Sat Nov 23, 2013 3:47 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
mr2angry2 sent me his Pilot Engine for a CSI and rebuild.

Bunch of my pics didnt turn out for crap will have to take some more tomorrow to replace these lol

Engine came well packed but the box had some damage as the UPS mutts must have tried to beat it to death on the way.

No damage done to the Engine.

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PostPosted: Sat Nov 23, 2013 3:52 pm 
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Location: Chicago
No shortage of rust on the crankshaft between the clutch and the Engine, was sanded off smooth so the Engine can come apart and so the bearing can be removed.


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PostPosted: Sat Nov 23, 2013 3:53 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
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Location: Chicago
Head removed no carbon build up looks like its running plenty rich.

Had to use a visegrips to pull the old head gasket off the head.

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Once I scraped off the residue lapped the head to ensure it was flat.

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PostPosted: Sat Nov 23, 2013 3:58 pm 
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Location: Chicago
Never seen a burn pattern like this on the top of the piston before.

Usually the carbon pattern is the other way around carbon in the middle then bare on the outside usually you don't see carbon washed off in the middle, almost like this piston was partially cleaned in the past?

Not sure what that residue is in the middle but its not part of the products of combustion.

The whole inside of the Engine smells like gas that has turned into varnish mr2angry2 you need to smell the inside of your gas tank if your tank is fouled you need to flush and clean your whole fuel system really good.

Has this Engine and or Pilot been setting for a long time?


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PostPosted: Sun Nov 24, 2013 4:25 pm 
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Location: Chicago
Removed all the studs scraped off all the gasket residue then lapped the top of the cylinder to ensure its flat, put a light hone on the cylinder its nice a straight, minor scuffing on the exhaust side now gone.


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PostPosted: Sun Nov 24, 2013 4:29 pm 
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Posts: 22512
Location: Chicago
The piston looks real low hour very little wear the ring seal looked pretty good, as found piston to cylinder clearance is .005 which is good and what I consider normal, if you install a new wiseco at .004 run it for 5 hrs remove it you will find about .005 clearance as the piston "sets" as its broken in .

If it was mine I would order a new set of rings and and reuse it.


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PostPosted: Sun Nov 24, 2013 4:30 pm 
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Location: Chicago
Stock 1990 Pilot reed cage and reeds, reeds look really good and don't need replaced.


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PostPosted: Sun Nov 24, 2013 4:33 pm 
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Location: Chicago
Studs all rusted to hell never seen this before, one the stud came out when I removed the nut on the cylinder.


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PostPosted: Sun Nov 24, 2013 4:36 pm 
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Posts: 307
Fuel was sitting a while with stabil In it
I will be flushing out fuel system and running fresh fuel for the future

The top end was recently redone and pretty sure it was bored to a .005-.006 clearance for the wiseco piston
I looked for oem but couldn't find anything

Once you measure cylinder lmk what you come up with".....
piston and rings are practically new . Hopefully can be reused.
I never ran heat cycles because it never ran properly after I put it back together after top end. Carb issues
I don't think I properly set ring gaps ..I don't remember what they measured ...that's why I sent it to the pilot Engine pro!!!! Thanks again looking great!!!


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PostPosted: Sun Nov 24, 2013 4:36 pm 
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Location: Chicago
Who ever replaced the top end last didnt clean all the old gasket material off :shock:


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PostPosted: Sun Nov 24, 2013 4:40 pm 
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Location: Chicago
Never seen all the timing marks all marked in white paint maybe this was for the 1990 engines?

Green arrow shows where the case will be modified for better oil flow.


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PostPosted: Sun Nov 24, 2013 4:42 pm 
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Location: Chicago
Cases split crank out


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PostPosted: Sun Nov 24, 2013 4:43 pm 
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Location: Chicago
Bearing came out stuck to crank will take it to my buddys and use his bearing puller tomorrow.


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PostPosted: Sun Nov 24, 2013 4:44 pm 
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I may have spare studs ..measure them and lmk what size they are . I have some from my odyssey Engine I never used.

What size will I need. I forgot what size I used


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PostPosted: Sun Nov 24, 2013 4:52 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
mr2angry2 wrote:
I may have spare studs ..measure them and lmk what size they are . I have some from my odyssey Engine I never used.

What size will I need. I forgot what size I used


Have any nuts too they are all really corroded they will rust easily in the future, all the corrosion protection is long gone, this Engine reminds me of a Pilot I seen towed on a open trailer in the winter and coated in salt.

http://www.partzilla.com/parts/detail/honda/HP-92900-10045-3B.html

Nuts

http://www.partzilla.com/parts/detail/honda/HP-94050-10000.html

EDIT
You also need two cylinder dowels one was missing and the other one was too short.

http://www.partzilla.com/parts/detail/honda/HP-94301-12200.html

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PostPosted: Mon Nov 25, 2013 1:23 am 
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Posts: 307
Ok I have 2 new studs here
Plenty of used nuts that are in good shape , but since I need to order the dowels I'll grab new nuts
I won't order anything until it's all torn apart


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PostPosted: Wed Dec 04, 2013 12:02 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
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Location: Chicago
Update

Cleaned up the cases, removed all gasket material, lapped the gasket surfaces to make sure they are flat and will seal, performed my oil passage mods on the cases, all they need is a final cleaning and assembled once the parts get here.


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PostPosted: Wed Dec 04, 2013 12:03 pm 
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Location: Chicago
Your gasket sets are here .


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PostPosted: Wed Dec 04, 2013 12:04 pm 
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Location: Chicago
Your two clutch side crank bearings are here (blue boxes) did you order the Yamaha bearings like seen in the red boxes for the mag side crank bearings? If so I will start to assemble your bottom end using my mag side bearing while I wait on yours to show up.


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PostPosted: Sat Dec 07, 2013 5:59 pm 
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Yes I have them together but was waiting to ship with final parts,,,,


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PostPosted: Sat Dec 07, 2013 6:51 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
mr2angry2 wrote:
Yes I have them together but was waiting to ship with final parts,,,,


Ok cool I will use one of mine and start the assembly of the bottom end :-)

How much are you still waiting on?


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PostPosted: Sat Dec 07, 2013 6:59 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Rings,,case studs,,case nuts,,,I gave all the seals and bearings


Just waiting to send all at same time


Looking good..


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PostPosted: Mon Dec 09, 2013 8:14 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
On the way to you tomorrow
Also put something in the box for you to put under your Xmas tree :)


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PostPosted: Mon Dec 09, 2013 8:25 pm 
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Posts: 22512
Location: Chicago
mr2angry2 wrote:
On the way to you tomorrow
Also put something in the box for you to put under your Xmas tree :)


Cool

Merry Christmas!


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PostPosted: Tue Dec 17, 2013 1:36 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Did you receive the rest of the parts?.


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