ALMOST THERE 76 LTD

[rcmatt007]

my other 76 engine (I thought I had two, but have two 77's and two 78/9's and a 78 block)

obviously in an accident: you can see the bock side of the mounting machine screw in the third picture

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[rcmatt007]

have two stubborn bolts so I am doing the propane heat and pb blaster treatment. If I have to split the case, I am assuming I will need to remove the heads?

[Fred Camper]

Or perhaps dropped really hard, but by definition a drop is also an accident so nevermind. BADDOG has a tig repaired engine mount as it also suffered a similar fate in its first life. Most like easier to repair than any internal damage.

[rcmatt007]

well, I am still hopefull I can get the OEM engine up and working right.... sitting on the stand, I did turn the crank and it shifted through all the gears and the external shift mechanism works fine.

[rcmatt007]

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back is off and nothing is loose.... I had the main shaft come off with it and looked inside and the gear had moved over.... OMG I thought, but when you put the shaft back in it works like it supposed to. I can feel the primary chain and it does not appear overly loose....

[Whiskerfish]

Yea that output shaft is a bit scary the first time you see it loose! That little access cover is there to help when you put it back together.

[rcmatt007]

I am assuming I will need to remove the heads to split the case.... I am not looking forward to that

[Whiskerfish]

Just the one side. Left IIRC. There are some good sized case bolts in there. Make sure you keep good track of where all the little bolts go. Seems like there are about 47 different lengths. Also I like to take pics of the gear shift stuff under the front cover. For some reason that thing mystifies me.

[rcmatt007]

rather amazing

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taking out the bolts, three big middle ones still too tight.... what a collection of bolts

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[Fred Camper]

This is not a collection of bolts, but a fine engine designed by knowledgeable engineers in Japan some 49 years back with skills exceeding many other motorcycle engine designers. Thank you for taking good care of this girl and she will certainly reward you for many years to come.

[rcmatt007]

opps the last picture was supposed to be the assortment of bolts holding it together

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[rcmatt007]

got the case apart... I do not think the shift forks were the issue. Now I am trying to figure out how to get the transmission gears out. one half was easy

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[rcmatt007]

got it out. I found three teeth in the crankcase, but 6 are broken. Methinks some PO drained three teeth out at some point.

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[rcmatt007]

have the fleabay transmission in.... it has all its teeth..... now the QUESTION.... do I put some sort of sealer when I put the two halves of the case together????

[CYBORG]

I use a thin coat of Yama-bond. Just for security