my 1100 rebuild/resto

[Gc33]

G'day mate - keeping up with your threads. Milestone day today, no more parts to go on at this time. It's no longer a garage queen:Outside 1.jpgOutside 2.jpgOutside 3.jpgOutside 4.jpgHad to put it in gear and ride it back in. Cheers

I'm very envious of you Ernest.... On 3 counts.... 1200 and looking nice... And running.

[Rednaxs60]

Thanks. Had it out for a short 50 Km ride yesterday, worked well. Bit different than riding the 1500. Mentioned to Sonya that I have to put some miles on it and her response was to do it soon as she wants to go for a ride as well.

Just bought a 1200 Limited edition frame with engine, CFI components - including ECU and hopefully the travel computer, wiring, all engine CFI components, with front end attached and an ownership/title. Might be rebuilding the engine, doesn't hurt to have a spare. Have some other thoughts on it as well such as with an ownership, strip and paint frame and other parts that are there and swap over to a new frame. Takes less time and can still operate the bike I have.

[Liam]

Ernest you are giving me inspiration as regards painting. That bike looks fantastic.

[Gc33]

Finished the 1100 aspy frame today to a standard where I'm happy with it... Now the 75 frame to prep and repaint....
I also got my 75 engine cases back from vapour blasting today. Never ceases to amaze me on how good parts come up from vapour blasting.

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[Rednaxs60]

While you have the cases apart, might want to change the internal bearings that support the alt shaft. engine output shaft (final drive shaft), and the small one for the transmission shaft - readily available aftermarket, just a thought. I had to replace the first two as theses were seized - don't know why, but these were.

[Gc33]

While you have the cases apart, might want to change the internal bearings that support the alt shaft. engine output shaft (final drive shaft), and the small one for the transmission shaft - readily available aftermarket, just a thought. I had to replace the first two as theses were seized - don't know why, but these were.

Yeah fully intend to Ernest. Once I figure out how to get them out.
I removed the water pump from its housing. Took a bit of doing. Looks like someone had loctite'ed it in there. It is still original Honda and bearing feels OK but reckon I'd be a fool not to replace it this far in..

[Rednaxs60]

The bearing for the transmission shaft should just pull out, not a very good friction fit. The alt shaft and output shaft bearings should have an opening in behind that you can get a long thin screwdriver/thin drift in behind to pop out, again, not a very tight friction fit. There is a small plate in behind the bearings that needs to go back in.

[Gc33]

I've had a win!!! My second engine has turned out to be a rough diamond... Bores are original and crank and bearings are almost perfect....

[Track T 2411]

[Gc33]

I had a stroke of luck today. Finally... After all the bad luck I've been having lately with corroded bores and a crankshaft scored... I finally bit the bullet.
After going into Harris engineering here in Perth and finding that I'm going to need a crankshaft plus bearings... I though bugger it I'll start stripping my spare 1000 engine. Quite rough on the outside so I wasn't holding my breathe but thought.. I've got nothing else to lose. I'm expecting the engine internally to be buggered.
I get it on to my engine stand and remove the heads and have a good look at the bores... Seem OK... Got my hone out with drill and give the bores a quick scuff to see if I can see any major defects.. None... Sensational.
So I set to and start splitting the cases... Water pump is bit average but still oem Honda.
I've got the left casing off and place on my brand spanking new bench purchased just for such an occasion... One thing I note as I've removed the clutch basket with gear shaft out that some of these bolts internally such as the oil splash guard and the pan behind the primary chain is very loose... Half undone almost.
With the left case on the bench I'm able to give a full hone. Comes up pretty mint... Except for a slight Ridge at the top of the bore.
I wipe the bore clean... Nice... Grab one of the pistons from my other engine.. Those pistons are marked 0.25 over. They don't fit... So the second engine is on its factory bores.. Awesome.
The pistons from it tho are cactus... A lot of slop in some of the ring groves and others the rings are seized in.
Next... I'm curious with bearings now... Something is gonna stop me... Everything is going swimmingly at present... Almost too good to be true... I remove the centre main bearing cap... Check journal and shell... Near perfect.. Put it back on.. Repat the process with the other 2...same deal.. Near perfect.... Righto... Check conrod journals... One at a time... Reassemble.. Check next repeat... All near perfect to the point I don't think I'll need bearings... Can't believe it... So happy at this point I crack a celebratory cold beer!!
So... Plan now is.... Rebore these casings to suit the pistons from the other engine.. 0.25 over. They are still quite fresh.
As for bearings... When I get back home from work next Thurs (I work in Fifo mining) I'll get the plastiguage/flexiguage out and Check bearings officially.