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 Post subject: Pilot Engine tear down
PostPosted: Sun Oct 19, 2014 6:47 pm 
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Joined: Thu Apr 22, 2010 11:38 pm
Posts: 1785
Location: New Mexico
Here is a spare Engine., it felt like it had good compression when you pull the cord. Since I am still waiting on parts to get my axles done, I figured what the heck I would l check out this Engine. I pulled off the stock clutch as I assumed it would need seals and found a mess. :shock: It must have shredded a belt somewhere in its life as the remains were still wrapped around the crank pretty bad and it completely took out the seal. With the clutch off it looks like they may have ran this way for a while as you can see the oil splash on the side of the case, honestly with the way the seal looked I am really surprised the Engine did not go poofkaboom. The crank is rusty on the seal surface and I will need to get it out to see if it will clean up or not. I assume the shredded belt held some moisture and caused the rust.

I pulled the cylinder off and it looks like maybe an 80mm Art piston. The piston looks pretty good to my untrained eye as does the cylinder but I have not measured either so I am only speculating at this point. The rod has "PROX" on the side is that a factory rod or is it an aftermarket? I have never had a Pilot Engine apart so this will be a learning experience for me, so please any and all input would be greatly appreciated. This is all I really did on it so far as I never intended to start to pull it apart quite yet. I need to wrap up a few other things & get organized before jumping into this, but I guess my curiosity just got the best of me once I found the seal issue. The crank doesn't spin freely so i am thinking the bearing are likely rusted or bad from the looks of how filthy everything else is.

I know we all love pictures so here are a few to start out, I really hope the crank will clean up & it will just be a simple rebuild...


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PostPosted: Sun Oct 19, 2014 6:49 pm 
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Joined: Thu Apr 22, 2010 11:38 pm
Posts: 1785
Location: New Mexico
A few more pics..


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PostPosted: Mon Oct 20, 2014 7:40 am 
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Joined: Mon Jun 10, 2013 8:59 am
Posts: 793
Nick, does it look like a full rebuild both top and bottom or just the top end?
The Aztec has been calling me:)

I haven't received the gaskets for the 500 so I might get started on the tear down of the Aztec.


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PostPosted: Mon Oct 20, 2014 8:34 am 
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Joined: Thu Apr 22, 2010 11:38 pm
Posts: 1785
Location: New Mexico
I think so, need to measure the top end to see if it needs bored but it looks the the best. The crank doesn't spin freely so there is an issue in the bottom end somewhere, hopefully just something stupid but I am never that lucky.


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PostPosted: Tue Oct 21, 2014 12:24 pm 
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Joined: Mon Jun 10, 2013 8:59 am
Posts: 793
I'm right behind you buddy with the Aztec. Hope to button up the 500 and get going on the rebuild. Any new progress? Please post pics of the bottom end disassembly if possible:)


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PostPosted: Tue Oct 21, 2014 12:33 pm 
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Joined: Thu Apr 22, 2010 11:38 pm
Posts: 1785
Location: New Mexico
Pilot bird wrote:
I'm right behind you buddy with the Aztec. Hope to button up the 500 and get going on the rebuild. Any new progress? Please post pics of the bottom end disassembly if possible:)


Will do, no new progress yet. ;-(


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PostPosted: Tue Oct 21, 2014 3:46 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
What a mess, looking at all he shit inside the Engine I would say its been running with the seal out for a while, surprised it did not rev to the moon and or seize up from the HUGE air leak, that bottom end has been apart before note the PROX on the rod, that is not factory.

Measure the width of the rod at the wrist pin bearing see if its still wide for the CR500.
https://www.google.com/search?q=prox+03 ... channel=sb

Plenty of pics located in my Pilot Engine CSI's viewforum.php?f=25


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PostPosted: Tue Oct 21, 2014 7:06 pm 
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Joined: Thu Apr 22, 2010 11:38 pm
Posts: 1785
Location: New Mexico
Thank you Hoser, is this the correct measurement?


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PostPosted: Wed Oct 22, 2014 7:14 pm 
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Joined: Thu Apr 22, 2010 11:38 pm
Posts: 1785
Location: New Mexico
Removed the Pull Start assembly & side case today and there wasn't a drop of balancer oil in it. :shock: Haven't cleaned anything up but so far everything doesn't look to bad. I ordered a flywheel puller this afternoon on feebay to be able to continue with the tear down. There's a little distortion right in the end of the crank where they have pulled the flywheel in the past..


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PostPosted: Thu Oct 23, 2014 7:01 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
The washer (red arrow) you left behind needs kept with the starter drive also verify the other washer for the bendix drive is their, I cant count the Pilot engines I have rebuilt that has had these washers missing, I even stock these washers it happens so often.

Check for how much metal dust is stuck to the magnet inside the trigger (blue arrow) also look inside the flywheel metal dust and DIRT accumulates their also, on the Honda Z50 engines the flywheel is your oil filter and is usually full of clutch dust, blow by sediment and dirt that has entered the Engine.

Fill the bearing up full with oil (green arrow) whilst the case is in storage this also protects the black rubber seal behind the bearing, carefully scrape all the gasket material off the case, use not chemical cleaners inside the case you can only damage the electronics or the bearing and seal, wipe out as much dirt as you can feel the need to wash it out then use 5w Engine oil to flush it out, then put the entire case inside a 2 gallon zip lock and zip it up to keep it dry and clean they are a dust magnet.

If you remove the key from the crank shaft it gets stuck inside the flywheel to a magnet for safe keeping and until you install the flywheel again, find the case dowels remove and stick them to the flywheel also these are the second most missing parts from a Pilot Engine not sure how they get lost and how they never get reinstalled but they do.


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PostPosted: Thu Oct 23, 2014 10:05 am 
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Joined: Thu Apr 22, 2010 11:38 pm
Posts: 1785
Location: New Mexico
Great info, thank you.

I have the dowel pins, I just removed them to make sure they would't get lost or damaged. That washer I had over looked, thank you it must have stuck to the case when I pulled it off, but I will be sure to keep it with the bendix drive.

Thank you for the heads up on cleaning the side case, my first thought would have been too clean it up in the solvent tank or squirt it with brake clean to remove any dirt from the case or stator.

I am at a stand still right now until the flywheel puller shows up, but hopefully I will get it this coming week.
http://www.ebay.com/itm/221003482237?_t ... EBIDX%3AIT

Thank you again sir.


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