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PostPosted: Sun Mar 11, 2012 9:39 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
adnoh wrote:
Hey mud, Tip: When you use the puller on the flywheel side install a flang nut on backward on the end of the crank to help prevent damage to the end of the crank. I see some that are damaged for excessive force and it expands the end out and screws up the threads. The nut will prevent the expansion from taken place or alest help control. I have even seen this damage from the mag being pulled using the correct puller where some used to much force to get off. Ask "H" about it and see what he has seen. Look forward to the new sleeve pics.


Right on I use the nut and washer from the flywheel and a additional 1/2" flat washer the two washers space the nut on the end of the crank out where its flush with the end of the crank then I use a flat piece of metal to further protect the end of the crank from the end of my puller or 'pusher' in this case.

You can see it all stacked up in the pic below, the two washers are their so no force is put on the threads of the crank all the forces pushing on the crank goes right through the washers into the shoulder machined on the end of the crank past the threads.

The ends of these cranks are softer than a grade 5 bolt.

Image

Above picture taken from the second page in this thread.
viewtopic.php?f=25&t=3948


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PostPosted: Sun Mar 11, 2012 12:45 pm 
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Joined: Sun Jan 09, 2011 5:33 pm
Posts: 319
Location: Cincinnati, Ohio
That nut on the end of the crank you are talking bout is that left or right threads?


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PostPosted: Sun Mar 11, 2012 1:00 pm 
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Joined: Fri Jan 12, 2007 2:17 pm
Posts: 3620
Location: Wichita ks
Its a right hand.


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PostPosted: Sun Mar 11, 2012 1:03 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Yes right hand threads I think its even one of them nuts your not suppose to reuse but I always do just clean up the threads really good on the crank and nut then use loctite on the threads then torque never had one come loose.


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PostPosted: Sun Mar 11, 2012 1:49 pm 
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Joined: Sun Jan 09, 2011 5:33 pm
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Location: Cincinnati, Ohio
Good deal ,, thanks


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PostPosted: Sun Mar 11, 2012 8:04 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
adnoh wrote:
Hey mud, Tip: When you use the puller on the flywheel side install a flang nut on backward on the end of the crank to help prevent damage to the end of the crank. I see some that are damaged for excessive force and it expands the end out and screws up the threads. The nut will prevent the expansion from taken place or alest help control. I have even seen this damage from the mag being pulled using the correct puller where some used to much force to get off. Ask "H" about it and see what he has seen. Look forward to the new sleeve pics.


Here you go ADNOH. Fresh LA SLEEVE 80MM with piston kit. Now, in the pictures you see on the intake side the sleeve needs to be cleaned up to match existing porting. How do you personally perform this task? Dremel with what grade bit?


Attachments:
OLD NY pilot engine fresh cylinder 001.jpg
OLD NY pilot engine fresh cylinder 001.jpg [ 44.02 KiB | Viewed 3784 times ]
File comment: another look
OLD NY pilot engine fresh cylinder 002.jpg
OLD NY pilot engine fresh cylinder 002.jpg [ 47.11 KiB | Viewed 3784 times ]
OLD NY pilot engine fresh cylinder 003.jpg
OLD NY pilot engine fresh cylinder 003.jpg [ 51.35 KiB | Viewed 3784 times ]
OLD NY pilot engine fresh cylinder 004.jpg
OLD NY pilot engine fresh cylinder 004.jpg [ 40.14 KiB | Viewed 3784 times ]
OLD NY pilot engine fresh cylinder 005.jpg
OLD NY pilot engine fresh cylinder 005.jpg [ 34.15 KiB | Viewed 3784 times ]
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PostPosted: Sun Mar 11, 2012 8:08 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
More pictures:


Attachments:
OLD NY pilot engine fresh cylinder 006.jpg
OLD NY pilot engine fresh cylinder 006.jpg [ 46.07 KiB | Viewed 3784 times ]
OLD NY pilot engine fresh cylinder 007.jpg
OLD NY pilot engine fresh cylinder 007.jpg [ 32.6 KiB | Viewed 3784 times ]
OLD NY pilot engine fresh cylinder 008.jpg
OLD NY pilot engine fresh cylinder 008.jpg [ 33.44 KiB | Viewed 3784 times ]
OLD NY pilot engine fresh cylinder 009.jpg
OLD NY pilot engine fresh cylinder 009.jpg [ 42.95 KiB | Viewed 3784 times ]
OLD NY pilot engine fresh cylinder 010.jpg
OLD NY pilot engine fresh cylinder 010.jpg [ 51.98 KiB | Viewed 3784 times ]
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PostPosted: Sun Mar 11, 2012 10:03 pm 
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Joined: Fri Jan 12, 2007 2:17 pm
Posts: 3620
Location: Wichita ks
Thanks for the pics. I use an air gridder with poritng bit.I post up a pic when I get back to the garage. Heres a pic of a Ex port on a cylinder I just altered today. Just started on the intake. post ya some pics when I get done.


Attachments:
New cut port.JPG
New cut port.JPG [ 90.43 KiB | Viewed 3779 times ]
Resize of IMGP8316.JPG
Resize of IMGP8316.JPG [ 123.97 KiB | Viewed 3779 times ]
Resize of IMGP8337.JPG
Resize of IMGP8337.JPG [ 73.38 KiB | Viewed 3779 times ]
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PostPosted: Sun Apr 22, 2012 6:51 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Crank and cases should be on the way to me this week, SPEED called !!!!!
I have all the new seals and bearings for the lower end, and a fresh new top end from LA SLEEVE is here as well with new 81mm piston kit.


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PostPosted: Thu May 03, 2012 6:18 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Went into the water pump side case tonight to just double check everything. After a close look I discovered the water pump impellar shaft seal appeared to be leaking. Also noticed the fins on the impellar were not in good shape as well. After removal of the water pump impellar, shaft I was correct in my discovery, there was damage to the shafts seal on the oil side of the case. My worry now is that this seal is discontinued. I'll post some pictures later tonight. I think I might have an alternative seal as this seal I removed looks identical to my Tecate impellar shaft seal for a 85 T-3 Tecate 3 wheeler Engine. More to come.

EDIT: More detailed FL400 Pilot water pump info found here viewtopic.php?f=1&t=8912


Attachments:
Nitrosport water pump 001.jpg
Nitrosport water pump 001.jpg [ 70.25 KiB | Viewed 3701 times ]
Nitrosport water pump 002.jpg
Nitrosport water pump 002.jpg [ 69.17 KiB | Viewed 3701 times ]
Nitrosport water pump 003.jpg
Nitrosport water pump 003.jpg [ 61.61 KiB | Viewed 3701 times ]
Nitrosport water pump 004.jpg
Nitrosport water pump 004.jpg [ 45.87 KiB | Viewed 3701 times ]
File comment: Are these seals still available?
Nitrosport water pump 005.jpg
Nitrosport water pump 005.jpg [ 52.99 KiB | Viewed 3701 times ]
File comment: Here is good view of damaged seal. I did not do this during the bearing removal.
Nitrosport water pump 006.jpg
Nitrosport water pump 006.jpg [ 62.04 KiB | Viewed 3701 times ]
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PostPosted: Thu May 03, 2012 9:33 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Service Honda order to be placed:
19217-PA5-000 Nut
19215-KA30710 Impeller
90201-413-000 Nut
90441-KA4-000 Washer
90454-KA4-003 Bearing
91201-148-003 Oil Seal

I am ordered 2 of each for stock, etc.

UPDATE everything still available but the impellar from Honda. I oredered 2 of everything listed and will look into ADNOH's advice in regards to a new impellar


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PostPosted: Thu May 03, 2012 10:10 pm 
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Joined: Tue Aug 03, 2010 12:02 am
Posts: 2147
Location: St. John, Washington
Those seals should still be availible. I believe they still use them on some newer quads.


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PostPosted: Fri May 04, 2012 8:11 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
don't throw that impeller away send it to me the next time you ship me something.

Looks like you found your wet line, the carbon buildup is one of the things you address annually when you remove the top end for an inspection, where does all that carbon go as it builds up and then flakes off or during a long wide open run when it gets a steady huge blast of heat and little parts of it starts to blister from the heat and flake off? spark arrestor catches some of it what about the stuff that is stuffed back into the Engine? http://pilotodyssey.com/PO/viewtopic.ph ... t=wet+line see the affects of the reverse pulse of the pipe....


Attachments:
wetline.JPG
wetline.JPG [ 111.82 KiB | Viewed 3687 times ]
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PostPosted: Sun May 06, 2012 8:09 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
that's not my cylinder Hoser, it is ADNOHS lol.
Can this impellar be used for the Engine rebuild? I forgot to order the parts over the phone Friday.


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PostPosted: Mon May 07, 2012 11:00 am 
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Joined: Fri Jan 12, 2007 2:17 pm
Posts: 3620
Location: Wichita ks
Yep, that cylinder pic of the carbon is one I was working on that was in need of a rebuild from a stock machine. In order to clean up mudds post you can delete it if you or mudd wishes. However the info is good.

Mudd I noticed there was a KA6 on the impeller pic. Look for the rest of the number that is a universal honda number and I would bet the impeller is used on other bikes. I would look at the replacment seal number and find what all machines it fits and I would bet the impller also would work. Theres a few company out there that make aftermarket impellers as well for more flow which is not really needed however would not hurt either. Good thing you choose to clean it up. Just gotta wonder where the chunk of impeller is or was. Look over the flow of the collant and start looking. Heck it could even be in the head. give it a shake. or in one of the line causing a blockiege be sure there clear. It could alos end up in the rad in the end cap rattling around or blocking a passage. Again how in the heck did it get brokeoff to begain with, just asking my self.


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PostPosted: Mon May 07, 2012 9:11 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Washed and completely cleaned the cases tonight in parts cleaner, then soapy water. Will let them dry out over night and hit with hair dryer just to be sure tomorrow. Bearings in the freezer as well. WILL TRY to start assembly hopefully tomorrow night!!


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PostPosted: Tue May 08, 2012 7:57 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Got the fresh re sleeved cylinder in today from LA SLEEVE,went to start assembly and I did not have a gasket set for the bottom end! I ordered a month ago when the project started 4 sets from WEED, got to see where they are and what the status is on them. Sucks man.


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PostPosted: Sat May 12, 2012 7:38 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Got gasket set today. Will try to assemble the bottom end tomorrow.


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PostPosted: Tue May 15, 2012 8:41 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Assembly put on hold. I might just leave it in pieces till I actually need this Engine. I have 1 already at Hosers which I purchased from NITROSPORT that will complete bolt in and go-does not make sense to assemble this currently. Toying around with idea of letting it be.


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PostPosted: Tue May 07, 2013 8:22 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Engine has been sent to hoser for a CSI and rebuild more to come!


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PostPosted: Wed May 08, 2013 10:21 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Mudbogger wrote:
Engine has been sent to hoser for a CSI and rebuild more to come!


3 boxes arrived took a quick look havent opened up all the little plastic boxes yet but didnt see a gasket set, only found the mag side crank seal other 2 case seals missing, you sent two clutch side crank bearings one box was marked as mag side but its actually a clutch side crank bearing inside, havent found the flywheel key yet might be in one of the boxes?

More later.


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PostPosted: Wed May 08, 2013 10:38 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
the key is in there hoser might still be in with the mag. also I am sorry for sending the wrong bearing and I forgot the gasket set. do you need just a top and set or complete as maybe I might have one at your compound still from previouz build?
let me know what I need to send over to you please. also the top and will need to be hoserized with the new sleeve.


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PostPosted: Wed May 08, 2013 4:39 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Hoser, I have the full gasket set here. I am sure I have the mag side bearing just want to make sure I send the right one as I must have mis labeled them-can you give me the number please if you have it? I might have to mic them to determine as I have aftermarket ones here as well as OEM in the boxes.Also your missing what seals on the bottom end? Do you need any dowels?


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PostPosted: Sun Jun 16, 2013 5:06 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Engine is now sitting on my bench rebuilt from the ground up, all bottom end gaskets, seals, bearings all new. All new water pump selas, shaft, impellar, all new fresh resleeved top end 80mm Wiseco, Boyesen reeds.


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PostPosted: Thu Sep 05, 2013 9:36 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Might be installing this Engine in the Throttle Pilot project, it is due here tomorrow, more to come.


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