Engine Reassembly #6

The cylinder head masked off and ready for paint.  This thing was a pain in
the ass to tape off.

Primed.

Painted.

Reassembly started with the cam chain rollers.

The valves looked terrible.

I taped off the stems and gave each one a quick bead blasting.  Good as new.

Under all of the carbon the valves were in good shape but since it had been
sitting for so long I figured it would be a good idea to lap them.

The valve seat after lapping.

The valve bits and torsion bars were pretty easy to install.

I notched out a piece of pipe to assist in twisting the torsion bars into
position.  I've seen a lot of people recommend cutting a notch out of a
socket to accomplish the same thing but scrap pipe was a lot easier to
part with than a socket.  Easier to cut and grind I would assume too.

Engine Reassembly #5

One of my goals with this project is to rewire the entire bike.  Mostly as a
learning exercise and partly to satisfy my obsession with everything on
this bike looking as close to new a possible.  Here is a shot of the stator
with the original (and very discolored) wiring.

Here is a shot with the new (color correct) wiring.  I used bullet connectors
and heat shrink tubing to try and get the best possible connection.  After
removing the old wires there wasn't a lot of extra room to work with.

Stator installed.

Neutral switch installed with the new wire leading off of it.  I'm just using
zip ties to hold the wires together right now.  Once I figure out how long
they need to be I'll remove the zip ties and use heat shrink tubing to bunch
everything together.

Another shot showing the stator cover installed.

Engine Reassembly #4

Masked and primed the cylinders.

It was a little tough getting decent paint coverage between all of the fins
without laying on too thick but I think it turned out pretty good.

After sitting for several years the cylinders definitely needed to be honed.

I bead blasted the piston crowns to get all of the built up carbon off of them
and then gave them a quick buff.

I installed a new set of rings on each piston and inserted into the bottom of
the cylinders.

Sliding the cylinders into place.

It took several tries to get things sorted.  I got everything installed on the
first try and then realized that in my excitement I had forgotten to install
the circlips so I had to remove the cylinders and pistons and start over.
On about the 5th try I got it right, circlips and all.  The black cylinders
contrast nicely with the bright aluminum color of the crankcase.

The pistons, back where they belong.

The "rebuilt" starter back in place.

Another view of the starter.

The starter sprocket and chain.

Engine Reassembly #3

With all the effort I've taken to make the engine look as clean and new as possible there was no way I could just bolt the crud covered starter motor back on.  I decided to completely disassemble it, clean it, paint the case and reassemble.  First I made sure that I could get a replacement if I happened to destroy it in the process.  They seem pretty affordable and plentiful on eBay so I  got to work.

40 years of abuse from water and road crud left the starter looking rough.

Only the cases are only held together by the 2 screws on the outside.

All the guts.

Masked off and primed after a good cleaning with degreaser.

A few coats of paint and they look brand new.

Ready for reassembly.

I have no idea what all these parts are called.

Greasing up the end caps and planetary.

I used a 25mm socket to press the bearings and planetary back together.

Planetary gears get a heap of grease.

Reconnecting the wiring.

I bead blasted the screws that hold the whole thing together and then gave
them a quick buff to make them match the stainless fasteners I'm using.

Engine Reassembly #2

Honda Bond isn't the easiest thing to squeeze out of a tube.

It's starting to look more like an engine.

Right-side-up again.  I taped the cam chain to the engine studs for now to
keep them from scratching the paint while I'm reassembling it.

Reinstalling the gear shift spindal and the rest of the gear shift drum was
pretty straightforward with the help of some photos taken during the
disassembly process and some printouts of the part fiches from BikeBandit.com.

The oil filter gear, clutch basket and oil pump go in next.

Another view of the engine so far.

The clutch center and plates.

A new set of clutch springs from BikeBandit.com

Clutch assembly complete.

A few more OEM parts.

The oil filter, cap, and kick starter spring are the last bits to go on.

Gasket set from OldBikeBarn.com.

The gasket was a pretty good fit.  New stainless fasteners finish it off nicely.

The right side is complete.

On to the left side.  The starter sprocket and the rotor go on first.