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PostPosted: Fri Apr 09, 2010 2:30 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Poofkaboomer !

The parts tell the story, cracked piston, broken ring, part of the ring missing make sure you check your entire exhaust system see if you can find the other part of the ring it went some place.

The piston was run way past its lifetime, all the factory machine marks are worn off the piston.

Engine came a dirty greasy mess you said the trans seal was leaking a while?

Sealed her up and off to the sink for a good scrubbing to remove the first layers so a autopsy can be performed without getting a bunch of crap inside during dis-assembly.


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File comment: Crack in cylinder behind the stud?
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PostPosted: Fri Apr 09, 2010 2:32 pm 
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Location: Chicago
After the bath at least removed the first layer..


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File comment: Heavy rust on the crank between the seal and the clutch
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PostPosted: Fri Apr 09, 2010 2:37 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
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Location: Chicago
After removing the head you can see damage to the top of the piston


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PostPosted: Fri Apr 09, 2010 2:38 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
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Location: Chicago
Rotate the crank and move the piston down you can see a ring snagged broke and what was left wore into the cylinder pretty deep.


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PostPosted: Fri Apr 09, 2010 2:39 pm 
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Location: Chicago
Here is the piston


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PostPosted: Fri Apr 09, 2010 2:46 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Next on my list is to go pull the studs out of the cylinder and put the cylinder on the boring bar and start boring it out to see how deep the damage goes and what size piston you will need, just as a guess it will be several bore sizes to clean it up..

Look at these next pictures that is RUST on the cylinder wall, after your done running this thing for the weekend or ride trip you need to let it idle with the choke on until you almost flood the thing, this will put extra gas and oil in the Engine, yes the gas will evaporate sooner or later but it leaves extra oil on parts, THEN every few weeks you need to hit the starter and let the Engine crank over a few times to keep redistributing the oil coating the parts, I do this on mine and they are in a climate controlled shop, if its raining at the end of the day when you put it away for the night do the same thing, worried about fouling a plug after you shut it off pull the plug and spray it off with carb cleaner blow dry then reinstall.


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PostPosted: Fri Apr 09, 2010 6:51 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Here is a shot with the cylinder at about 80.35mm


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File comment: First pass
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PostPosted: Fri Apr 09, 2010 8:52 pm 
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Joined: Wed Jan 10, 2007 9:08 pm
Posts: 191
Yes The Trans. Has been leaking I guess for a long time. This is not my ride but a fellow N.J. rider that I am mechanically rebuilding for him. It's a real mess. He got it out of Conn. It is Lowrider's old piece. Years of neglect & outside storage dry rotted, rusted and sun bleached everything. The list goes on everytime I get deeper into the machine. But when I get done with it, He will have a solid piece. A favor for a fellow rider and friend. It will be ugly it will Kickass and have alot of time and money spent on it .....But it is one less Pilot parted out......I need help finding the following.... Seal 91223-VM0-004.... Bushing 53215-950-000... Thrust 53224-HE0-003.Part # for front ball joint Boots..Front New or Used Works shocks..Thanks Hoser for this site could not be doing this without it and it's Members. Rich a.k.a Pilotdick..


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PostPosted: Sat Apr 10, 2010 8:16 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
PilotDick wrote:
Yes The Trans. Has been leaking I guess for a long time. This is not my ride but a fellow N.J. rider that I am mechanically rebuilding for him. It's a real mess. He got it out of Conn. It is Lowrider's old piece. Years of neglect & outside storage dry rotted, rusted and sun bleached everything. The list goes on everytime I get deeper into the machine. But when I get done with it, He will have a solid piece. A favor for a fellow rider and friend. It will be ugly it will Kickass and have alot of time and money spent on it .....But it is one less Pilot parted out......I need help finding the following.... Seal 91223-VM0-004.... Bushing 53215-950-000... Thrust 53224-HE0-003.Part # for front ball joint Boots..Front New or Used Works shocks..Thanks Hoser for this site could not be doing this without it and it's Members. Rich a.k.a Pilotdick..



Glad to see its being saved.

Do a search for ball and joint and boot their are all kinds of info here is a few viewtopic.php?t=3708&highlight=ball+joint+boot
viewtopic.php?t=237&highlight=ball+joint+boot

Honda does not have the parts?


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PostPosted: Sat Apr 10, 2010 8:19 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Took the right side Engine cover off then pulled the flywheel and discovered Honda never installed the retainers that hold the balancer shaft in place I have no idea how it stayed in place all them years I guess it was running real true so never moved .

The side cover has never been off you can see the dark oil stain on the upper bolt hole, their is no tell tale signs of loctite in the holes.


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PostPosted: Sat Apr 10, 2010 8:21 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Cases are split, I will work up a parts list later.

Any mods on this Pilot or Engine or is it all stock?


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PostPosted: Sat Apr 10, 2010 10:31 am 
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Joined: Wed Jan 10, 2007 9:08 pm
Posts: 191
Stocker for now..


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PostPosted: Tue Apr 13, 2010 10:54 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
PilotDick wrote:
Stocker for now..


Here is the parts I will need, all the parts numbers are HONDA part numbers I like to use all HONDA when ever possible they are the best quality, you will need a 81mm wiseco piston I think rockymountain has the best price?

Notice at the end of some of the descriptions their is a quantity Need TWO for those items I will need TWO of them..

13111-HE0-000 Pin, Piston
90601-KA5-000 Clip, Piston Pin Need TWO
91003-HE0-003 Bearing, Connecting Rod Small End
94301-10160 Pin A, Dowel Need TWO
94301-12200 Pin A, Dowel Need TWO
94301-14200 Pin A, Dowel Need TWO
90028-MA6-000 Bolt, Special Flange Need TWO
91012-HE0-000 Plate, Bearing Setting Need TWO
91032-HE0-005 Bearing, Radial Ball
91033-HE0-005 Bearing, Radial Ball
91203-HE0-003 Oil Seal
91204-HE0-003 Oil Seal
061A0-HE0-000 Gasket Kit
91201-402-015 Oil Seal
91201-148-003 Oil Seal
14132-KAE-000 Gasket A, Reed Valve

Need a 81mm piston
Here is the best price on the piston?
http://www.rockymountainatvmc.com/produ ... icleSelect

$124.99

Thanks.

Oh be sure to check here for a rockymountainATV promo code discount thing...
http://www.pilotodyssey.com/PO/view ... 1&start=15


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PostPosted: Tue Apr 13, 2010 12:05 pm 
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Joined: Wed Jan 10, 2007 9:08 pm
Posts: 191
will order tonight 4-13-10..thanks rich


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PostPosted: Tue Apr 13, 2010 12:12 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
PilotDick wrote:
will order tonight 4-13-10..thanks rich


Thanks, cases are cleaned, lapped, hoserized soon as the parts get here I can assemble.

Cylinder is about 1/2 done once the piston is here I can finalize the bore then hone etc.


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PostPosted: Sat Apr 17, 2010 1:06 am 
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Joined: Wed Jan 10, 2007 9:08 pm
Posts: 191
Drop shipping all Service Honda parts to you.. Piston will have to send to you when I get it..


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PostPosted: Sat Apr 17, 2010 8:34 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
I might have a Piston if you need it fast.


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PostPosted: Wed Apr 21, 2010 1:28 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Mudbogger wrote:
I might have a Piston if you need it fast.


No were good thanks, actually I have a 81mm here and will probably use it if his don't show up by time I need it.

All the parts from Service Honda are here, I verified the order.

Started assembling the bottom end.


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PostPosted: Fri Apr 30, 2010 7:19 am 
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Joined: Wed Jan 10, 2007 9:08 pm
Posts: 191
I shipped out the piston on Tue.4/27..


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