Their are bosses CAST into the cases for disassembly here is some pics of a few.

Here is what happens when you use a wheel puller to remove the recoil basket.

Wires just outside the Engine the tape soaked with oil falling off.

After removing the sticky mess I find someone had twisted and taped the wires together, they were not attached, wonder how many times they changed and or charged the battery thinking the battery was a problem?

This was a trail side repair that never got fixed right?

I soldered in a piece of wire so all the wires are the same length again, I used some elevator wire meaning its the wire they use on elevators to feed the controls inside the elevator, its very flexible, great for vibration and below zero temps, if your ever on a construction site and see the elevator guys ask them for some they always have a big chunk left over from a install, its a air craft quality item and usually FREE

You know I have seen wiring like that in many houses and buildings. That guy gets around. Keep up the good work, that poor Engine has been mistreated. Talk to it "H". Go riding and cool off a little.

elevator wire huh-I'll see if I can get some for the group on the many sites I visit---

Morebeer probably has a bunch of it ....

LOL-wheres he been-havent heard from him in a long time-he posted lately?

LOL this whole thread is meant to heat people up, get them thinking, teach them, show them what NOT to do, this is the perfect Pilot for a what not to tutorial this Pilot is well used and abused, never been well maintained, shows signs of rooky wrenching and maintenance, poor work habits, nobody is born with good mechanical skills and work habits they are acquired, learned, taught by others, you don't find this stuff in any Service Manual, stuff you see here is hard to put a price on, the whole purpose of my site is to enhance human performance, hopefully install good work habits into peoples minds, show the way to guys new to the wrenching arena, I was lucky in my early years I was taught by the best, taught by guys that stopped at each step of the way during the process of doing something and explained what and why they were doing it that way, when they seen me doing something stupid they rode my ass so I would never forget, they followed simple rules like for every action their is a reaction, plan your work work your plan, slower is better, observation and attention to detail is very important etc.

I hope people are reading and thinking about whats in this thread and not just skimming through it trying to be entertained for a few minutes of their life, hopefully after reading all this and leave they will take away with them some new knowledge and skills that will help them the rest of their lives, I hope they look close as I am no teacher lol

Yes Hoser, I think I have already learned a couple of nice lessons from this thread, thanks for all the detailed info.

Getting closer to being done

Speedchaser head

Hoser! After reading that stirring and inspiring post,I'm thinkin' the guys need you to do same on:
1- How to pick/select the perfect woman!
2- How to maintain a perfect marriage! (or does #1 deal also take care of #2?)

I have no advice for married guys other than don't do it a second time haha

How many weddings you been to when they get to the part for better for worse, sickness and in health, until death do us part and the groom hesitates or messes it up lmao? At mine their was a long moment of silence whilst I was thinking about what I was going to agree to

More progress today, here is the reed cage, you can see the dirt that got past the K&N

Makes you go hmmmm huh

A NEW manifold will be used and the old rock hard one will be dicarded, the NEW manifold is http://pilotodyssey.com/BTmanifold.htm AND http://pilotodyssey.com/BTmanifold2.htm





Hare you ever get a 39mm carb?

Ok another update, radiator installed, cooling system button up ready to fill, carb and air box installed, rear suspension 1/2 finished.

Hare you never replied on the carb issue so I am selling you my modified 39mm PWK for 125 bux installed
if you get a different carb you can send this one back for a refund, I really didnt want to sell but your Pilot needed something the old stock carb still has the choke plunger corroded in the carb body.

Pics of the hoserized carb http://pilotodyssey.com/cpg/displayimag ... m=36&pos=1

Theory here is to straighten the air before it enters the carb after that tight 90 degree turn it makes in the rubber boot.

Left on the list of things to do.
Finsih rear suspension
install clutches
fill coolant system
fill trans and balancer oil cases
flush gas tank mix and install few gallons of fresh gas
replace front right spindle
go through the front brakes and adjust
inspect front suspension parts
evaluate front bumper
change ignition switch
change choke cable
look for more rigged up crapola on the Pilot and correct, I seen a bunch of the plastic bolting that is not right...

I am sure their is more this is just a list off the top of my head.

The screen theory has been proven a myth while testing many different engines on a dyno. All the engines were four strokes, making 500-600 hp. Each Engine gained roughly 25-50 hp by removing the screen. The screen does work in front of a MAF sensor to help create a cleaner signal to the ecm Only when someone has modified air intake piping and cause unwanted turbulance to the sensor. I would be curious to see how the screen affects a two cycle on a dyno and or throttle response. Every Engine and set up can react differently to the same type of modification.

The honeycomb flow straighteners used in industrial applications right before a air station (monitors air flow in the system on the fly) work great, I have seen this first hand when doing testing and balancing on large systems, they usually end up over time getting plugged with dirt, some get so plugged with dirt the force blows out the fragile honeycomb, we take flow data manually before removing them, then took flow data after removing them the system would never run right after they were removed because the air station was confused by all the turbulence and stratified air across the flow station monitor, so we replaced the honeycombs then checked the flow again, once replaced the air station functioned properly.

We also learned they restrict flow (no shit anytime you reduce volume of an area it reduces flow) the restriction and pressure drop is calculated and designed into the system so is not a issue for the HVAC system.

I gustimated the carb will now flow like a 38mm but if it should flow like a 37mm or even a 36mm its more than big enough for this application and use, I could toss it in the lathe and safely bore it to a 40.5mm or as other getting on the edge 41mm, I don't think it needs this.

Flow was not a concern when I did this mod, straightening air flow after the tight turn was the concern.

Having worked on huge HVAC systems trouble shooting them finding damaged and missing turning vanes in elbows I think what the Pilot really needs is to add turning vanes in the elbow, we have diagnosed turning vanes that were right before an air station, after restoring the honeycombs their was a improvement in flow even though the turning vanes in the adjacent elbow were not repaired, after repairing the turning vanes at a later date (plant shut down) the flows increased even more and the system stabilized.

Anybody know how we can mold a new intake boot for the Pilot, one with a larger ID would be nice for the larger carbs..

Got the Pilot to the point I could start it and heat cycle but guess what NO friggen spark!

This Pilot is haunted!

Found the black and yellow wire on CDI (Capacitor Discharge Ignition) corroded and broken off, looking at the corrosion on this Pilot I am under the impression someone dunked or soaked this entire Pilot in salt water, maybe they took it for a ride in the ocean?

New anti theft lug nuts.


4 wheels, to remove you need THREE DIFFERENT size sockets because each tire has a different brand or style lug nut, dunno who the dumbass is that's responsible for this shit but hopefully he reads this and feels stupid as he really is,

WHO in their right might puts miss match lugs nuts on each wheel?

Your life is not aggravating enough you need to create more aggravation for yourself?

DUNBASS I bet you spent more money on your last 6 pack than it would cost you to BUY the RIGHT LUG NUTS!

The left rear of this Pilot is trashed, the mounts for the lower links are not only bent but the holes are slotted, it looks like someone drove the Pilot a few thousand miles with the bolts loose, some attempt was made at welding on washers then run it again allowing the washers to be slotted, to add insult to injury the lower frame tube is bent, the end result is the left rear tire is toe in real bad and the top of the tire is leaning in, I straighten all the lower links and this helped but the toe is still not right.


When I bought my Pilot it came with the lower links all mangled up, then I could not afford to buy new so I took one of the old ones and put a hiem on one end so I could adjust the suspension, this worked for years until I could afford new links, I dug out my old adjustable link and tried adding it to this bent up frame, it helped some but did not have enough adjustment to get the toe completely right, I think its going to need a full set of adjustable links so the suspension can be properly aligned.

I started a post . http://www.pilotodyssey.com/PO/view ... 5189#45189

wow-that Pilot is cursed!!
Quick Hare get it before Hoser explodes!!!

Rather than use the link with the hiem I took a link that was kinked and cut out the bad part then put a tube in a tube and welded it up.