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Mudbogger FL350 Engine CSI Complete Rebuild
http://www.pilotodyssey.com/PO/viewtopic.php?f=26&t=3596		 Page 1 of 5
Author:  hoser [ Thu Oct 18, 2007 8:54 pm ]
Post subject:  Mudbogger FL350 Engine CSI Complete Rebuild
Mudbogger sent me one of his 350 engines for an CSI.


Nice packing job...

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Author:  hoser [ Thu Oct 18, 2007 8:55 pm ]
Post subject: 
Crank not rusted real bad, some wear on the cases by the Engine mount.

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Author:  hoser [ Thu Oct 18, 2007 8:57 pm ]
Post subject: 
You can see piston scuffing through the exhaust port, you also can see the 'wet line'

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Author:  hoser [ Thu Oct 18, 2007 8:58 pm ]
Post subject: 
Water in these pockets.

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Author:  hoser [ Thu Oct 18, 2007 9:04 pm ]
Post subject: 
The cylinder has a new sleeve but who ever installed it never matched the ports of the new sleeve to the old sleeve and cylinder they also did NOT bevel the ports, they used a WISECO piston and never drilled the lube holes and it looks like they never relieved the exhaust bridge, not surprised the piston is scuffed.

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Author:  hoser [ Thu Oct 18, 2007 9:06 pm ]
Post subject: 
The bottom end, will know more once the cases are split.

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Author:  mudbogger [ Fri Oct 19, 2007 5:23 pm ]
Post subject: 
Thanks Hoser-I'll contact the old owner of this motor (( Internal Combustion Engine ? )) as I just recently bought it for this ody I am currently doing.He had sold it to me under the pretense of it being a 20-30 hr motor (( Internal Combustion Engine ? )) that was recently taken out of a parts machine, he had no other info on it but had mentioned it was rebuilt recently, so I guess the descprition fits the motor (( Internal Combustion Engine ? )).The piston is a Wiseco huh?Wonder why, new sleeve in it why not go with a Honda ART Piston?-have you had the chance to size the bore by chance?
Thanks for the great pictures BTW-the wet line isnt that far from that piston, I havent seen 1 that close to date-could there have been an issue?have you seen the plug I sent by chance-
Also, why resleeve and not drill the cooling holes in the piston-thats the wierdest thing so far IMO-they have it written on the piston box and inside the directions as well.
Author:  hoser [ Mon Oct 22, 2007 4:03 pm ]
Post subject: 
The piston OD is 3.141

The cylinder ID is 3.151

Skulls NEW wiseco measured 3.143 OD even if wiseco sends you a new piston and it happens to be the same size as Skulls was that would leave you with .008 piston to cylinder clearance...
Author:  Ody_Stable [ Mon Oct 22, 2007 4:40 pm ]
Post subject: 
That's too tight according to the brand master Liewire!
Author:  hoser [ Mon Oct 22, 2007 7:49 pm ]
Post subject: 
I put a couple of match marks on the flywheel and starter gear before taking it apart .

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Author:  hoser [ Mon Oct 22, 2007 7:50 pm ]
Post subject: 
Recoil basket and ring gear removed

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Author:  hoser [ Mon Oct 22, 2007 7:54 pm ]
Post subject: 
To pull the flywheel you use a puller like this, this puller fits about 1/2 the flywheels Honda uses as well as many other brands.

I think I paid like 15 bux for it at my local Honda dealer about 15 years ago.

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Author:  hoser [ Mon Oct 22, 2007 7:56 pm ]
Post subject: 
Now you can see the stator, you remove the 3 bolts (red arrows) to remove the stator plate.

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Author:  hoser [ Mon Oct 22, 2007 7:56 pm ]
Post subject: 
Stator plate removed.

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Author:  hoser [ Mon Oct 22, 2007 7:57 pm ]
Post subject: 
Bolts that hold the stator plate have thread lock on them..

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Author:  hoser [ Mon Oct 22, 2007 7:58 pm ]
Post subject: 
In the tub ready for a bath.

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Author:  hoser [ Mon Oct 22, 2007 8:01 pm ]
Post subject: 
With the first layer of grease and grime removed its time to remove the balancer gears.

Cover off, see the match marks for the balancer (red arrows) the big nut that holds the balancer gear on the crank has a stamped steel lock you bend to keep the nut from coming loose, (blue arrows) it needs replaced it has been removed a few times already and is in rough shape.

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Author:  hoser [ Mon Oct 22, 2007 8:03 pm ]
Post subject: 
Gears removed.


Next I split the cases, I started fabricating a puller plate I will finish that tomorrow and split the cases.

See the balancer oil dip stick?

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Author:  mudbogger [ Mon Oct 22, 2007 8:55 pm ]
Post subject: 
Ok, so far I need the following:
Piston-hopefully ART I'll call Sara and ask what they have-the size I need is ?
Head nut- 1
reed cage bolt-1
cylinder nut-1
Balancer gear washer/nut-1 of each
full gasket set
anything else so far?
Probably new bearings and seals for the bottom end as well I would imagine.
Author:  hoser [ Fri Oct 26, 2007 4:57 pm ]
Post subject: 
Ok I once again got side tracked for a few days and took advantage of the nice outside weather to make some progress on some outside projects I been trying to finish, sorry Mudbogger for putting you on the back burner but I am pretty sure you have other running toys and wont mind :-)

Anyways, I made a adapter plate so I can use the case splitter I use for the Pilot on 350 cases also, it also gives me room to expand to other engines by locating and drilling more holes.

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Author:  hoser [ Fri Oct 26, 2007 4:57 pm ]
Post subject: 
The cases split easily

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Author:  hoser [ Fri Oct 26, 2007 4:59 pm ]
Post subject: 
FAG bearings from Germany

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Author:  hoser [ Fri Oct 26, 2007 5:00 pm ]
Post subject: 
Oil passages to the bearings will be hoserized.

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Author:  hoser [ Fri Oct 26, 2007 5:11 pm ]
Post subject: 
Mudbogger wrote:
Ok, so far I need the following:
Piston-hopefully ART I'll call Sara and ask what they have-the size I need is ?
Head nut- 1
reed cage bolt-1
cylinder nut-1
Balancer gear washer/nut-1 of each
full gasket set
anything else so far?
Probably new bearings and seals for the bottom end as well I would imagine.


Does the full gasket set come with the orings like a Pilot kit does?

I need that big o ring in the the pics, all the blue arrows are pointing to what I need.

O ring (in the pics)

Both crank seals

Both crank bearings

TWO case dowels one is damaged one I have not tried to remove yet


::-:
Author:  mudbogger [ Fri Oct 26, 2007 8:01 pm ]
Post subject: 
Ordered the crank bearings, a complete piston kit at 80.5 mm( with rings, clips), wristpin bearing,and case dowels tonight Hoser.I have a complete gasket set that includes the o-rings, got the reed cage bolts, the pull start case bolts as well.I have to order the jug nuts,new reeds, from Service. along with some other minor items as well.Parts to me for cases be here by WED of next week.
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