Here we go. My first CSI on a Pilot internal combustion Engine.I have so much stuff at Hoser's currently I figured I would for once do 1 of my internal combustion engines myself here. I first want to say in no way is this a snub to Hoser, he has and always will rebuild my internal combustion engines. I have him totally overwhelmed currently with my LT Pilot project,Turbo's 350, 2 Tecate internal combustion engines, a 250r atc internal combustion Engine and the LT internal combustion Engine currently.That is alot to ask of a guy not to mention his all the other internal combustion engines sent to him.
Ok first thing first. I have rebuilt several Tecate ATC intenral combustion engines and 250r as well,so I have the ability and currently the time to get this apart and get going.I cannot bore or hone cylinders but can pretty much do all other mods and such as per Hoser's pages. After removal on the internal combustion Engine a general look at the exterior gives 1 a suspicion there might be a really really good chance this needs to be split down and checked.
First thing -
compression way down-head bolts wrong- these will be replaced
Dowels on rear for mounting plates to trans have been crushed by improper installation.
Rear studs on jug either not screwed into the cases fully or wrong studs.
Reed cage bolts mismatched and wrong.
Side case bolts (2) wrong pitch/thread
Crank has grooves in it probably from a skill billy clutch removal session gone bad.

Have at it Mud
we all have faith in you
You can do it Just post a lot of pic's

Speed

Hello Speed.
Thanks for the encouragement!
Can I get a front bumper please????? Pilot!!!

Old owner told me he had the top end recently done by local shop. He had documentation for 82mm Wiseco, bore,reeds and labor.
First, the compression tells me something is amiss at the 150 psi warm with a 82mm IMO that's low. I took the pipe off and looked into the cylinder. No good, can see gouges. Took the stock OEM head off and here is what I saw. He was right brand new Wiseco 82mm Piston.
Cool deal. At least I know the old owner was telling me the truth.

But as we progress along with the piston CSI and the jug we see this:
Piston is way loose in the jug and a quick check you can see the numbers. Way too much clearance.

Head gasket was not leaking and the top of the jug and the head is in good shape,can be reused.

Jug off and the damage is pretty bad. This piston is brand new-it has no hrs on it at all, probably never ran it after the rebuild by local shop.
I am trying to figure out what happened here. Perhaps a piece of old ring was left in or around the bottom end and was pushed up? Perhaps improper lubrication on the new piston when installed? The aluminum is exterior on this piston, it can be scraped off. Your thoughts please.
There was no piston prep what so ever-the piston pin has to be hammered into the piston-the skirts are sharp and there are gouges in the wristpin holes from a skill billy. A quick measure of the bore on top is 81.63mm but there is gouging on all sides on it.

Reed cage removed.Not 1 ounce of sealer on it at all. Nothing. Unreal. Must have leaked like a air hose with no fitting in it.

Pictures of the piston.

Both side cases off, starter removed,flywheel pulled, balancer out, mag and associated case internals removed.I have damage by the balancer inside the cases. See pictures. Is this a common issue with these to have scratches like that? Please remember this is my first Pilot internal combustion Engine. Also the side case plate which houses the bearing for the balancer has damage as well, it was heavily silicon ed.

Will split the cases today more to come!! I will with Speed's consent send the crank over to him to see if those gouges can be fixed and perhaps a new CR 500 ROD KIT installed. I must make sure the runout on this crank is well too.
I have checked the bearings removed so far for retainer issues as we have documented with the crank bearings and have found none to date. The side cases mag side appears fine, no issues. The internal damage especially by the balancer is a worry to me.

Cases split. Noticed some area of concern, especially in the balancer race area.There are as shown in the pictures so deep gouges. The balancer itself is damage free, so I assume the Engine has been split before and a bearing spun in the area pictured.

Damaged area just below the cylinder stud. I cannot see how the stud was not leaking air in this case. Any thoughts? I am going to have to see if Speed has time to weld this, or would a simple JB WELD in the area pictured be good enough?
Also the reason for the studs being higher in the back of the cylinder was due to skill billy workmanship, they were not tightened all the way into the cases. Stupid stuff by some skill billy.

Case split with my TUSK universal tool. Thing was a great tool to pick up!

Bearing pictures as is right after the cases were split. Ever wonder where that metal goes when you smoke a piston? Look closely and you'll see it. It was as is pictured after I removed the seal. Glad I took this thing apart.

More. I checked the retainers on both bearings and they are still in place. A quick spin of the bearings and they feel ok but at this point they are going to be replaced.
Now back to the seal issues. The right side seal is double lipped for sure.

Side case and crank going to SPEEDCHASER for repairs and rod replacement, cylinder is packaged and going to LA SLEEVE for a new sleeve and piston kit. Should be a week to a week and a half for that to return.

Got email from Randy Bridgewater @ Odysseysalvage,com my bottom end crank bearings and seals are in transit as we speak. Cases and crank are at the SPEEDCHASER compound. Jug is also at LA SLEEVE and will have fresh sleeve and piston kit installed.CARB PARTS ARE ORDERED FROM carbpartswarehouse.com AND ALSO ARE IN TRANSIT!

Randy shipped seals and bearings to wrong address. Hoping he can get the USPS to reclaim them!

With an 82mm piston, what were you expecting the compression psi to be at? Not being condescending but I'm just curious to know..

Hello! No harm asking! I expected it to be around 165+ since stock is around 149 on a 80mm. Most of my 81mm + with speed heads run around 172psi give or take. I also took the exhaust off and looked quickly up the port and noticed the gouges on the piston surfaces. Of coarse psi varies with each jug.
Never got my bearings from Randy, only seals finally. I am happy to get them even! Do not know what is going on there but he did me right with shipping so I am happy. I got the bearings myself anyway.Still awaiting the left side bearings for this rebuild. Speed called today and asked for the balancer and bolts for the cases as in the thread you can see the damage to the bearing surfaces where the balancer turns.

Sent the balancer, cases bolts and side case cover that holds bearing for the balancer to SPEED today for fitment issues. Speed wants to make sure the bearing surfaces for the balancer are good to go before diving into the case halves any further.As pictured in the thread is appears that the clutch side bearing that holds the balancer failed and hence the damage pictured. He may have to fix these areas for proper fitment.

L A Sleeve called jug was resleeved, new Wiseco piston kit with it is on it's way to me, should be another week at most. The cases are still at Speedchasers and I have all the bottom end bearings,seals, everything to start rebuilding from bottom to top here waiting.

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.

Thanks for the tip sir. I will do so on the next project for sure.