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Repair & Maintenance Having problems? Doing a rebuild? All Repair/Maintenance Discussions here.

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post #71 of 95 (permalink) Old 06-20-2019, 10:27 AM
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I remember my 1st bike motor split too. I didn't have a service manual, was just a kid so I just tore it all apart. I had a local shop rebuild my crankshaft with a new rod kit. Putting the trans back together took me several hours. It was a trial & error gears & washers stacking exercise getting the dogs facing and meshing in the right directions and the assemblies mating up and functional with the shift drum and forks. By the time I got it all back together right I had taught myself how that trans worked though. From that day forward I felt fearless and began to split cases for other folks.

I remember the 1st automatic trans for a car that I built too. Those memories still stand out the brightest to this day because I had never challenged myself so completely and so technically up to that young age. The only reference that I could find was a cutaway view of the major parts assembly, a hydraulic circuit diagram & valve body cutaway views, along with the general clearances and torque specs listings. I studied those cutaways for hours and days on end... probably a month or more, building enough courage to spend all of my saved up cash. I was just an anxious kid in middle school spending money I had earned fixing cars.

I bought a complete high-perf B&M rebuild kit, new sprags, a B&M stall converter and a B&M valve body shift kit. I was terrified of it!!!! So I took it apart very slowly, studying everything as I went. By the time I got everything cleaned and prepped for the gazillion reassembly steps I felt a lot more confident though. That 1st one was probably one my best efforts ever too, as far as the amount of time I invested in it and all of the double & triple checking that I did as I slowly and carefully assembled it to high-perf specs. It was the only auto that I ever built for myself that I did not ever tear up too! I scattered the rearend on the road before that happened and sold off that trans. :-)

Given enough time, tools and careful study most folks can build anything they want to, once they give themselves a try... :-)
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post #72 of 95 (permalink) Old 06-20-2019, 10:40 AM
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Originally Posted by bcsman View Post
If I was younger I'm sure these new adventures would not slow me down or stop me from engaging. I'll bet most of the veterans here started out at a younger age so now it seems like nothing to split, tear down, and repair, do it with your eyes closed. But at my age and lack of mechanical experience it seems like a larger hill to climb so don't think too much less of me for going the route I am. I WILL get things fixed and the help and enthusiasm I get here helps immensely. Many thanks for patience and advise!!!!
Ya, you are a LOT smarter now that you've aged a bit! Gone are the 10 foot tall and bulletproof attitudes of your youngster years... but that is a good thing! You'll make fewer mistakes now. Costs will go down and quality will go up! Celebrate all that!

I know I don't miss my younger days at all anymore. Its a miracle that I survived. You're doing fine!


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post #73 of 95 (permalink) Old 06-20-2019, 11:38 AM
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Quote:
Originally Posted by retro View Post
I remember my 1st bike motor split too. I didn't have a service manual, was just a kid so I just tore it all apart. I had a local shop rebuild my crankshaft with a new rod kit. Putting the trans back together took me several hours. It was a trial & error gears & washers stacking exercise getting the dogs facing and meshing in the right directions and the assemblies mating up and functional with the shift drum and forks. By the time I got it all back together right I had taught myself how that trans worked though. From that day forward I felt fearless and began to split cases for other folks.
Sounds a lot like my first case split.

Mine wasn't that long ago.

https://www.hondaforeman.com/130-for...-cleaning.html

https://www.hondaforeman.com/130-for...eassemble.html

Once you do one, you aren't scared of them anymore and you undoubtedly get brave and dump everything the next go round, and it takes you twice as long.

What I have learned on these transmission is, get it back together where it all spins smoothly, and rotate the shift drum while spinning the transmissions shaft to see if it will shift through all the gears and back.

Then bolt the cases back together, and do it again.

I put the wife's 420AT motor ALL The way back together and put it back in the bike, to find I'd bound the shift drum so it wouldn't shift. Had to pull the motor back out, take it all the way down again, and just loosen the crankcase bolts a hair to unbind the shift drum, then put it all back together and it worked fine.

Check and double check while putting it back together, and if you run into a hiccup, stop and ask here. It's just lego's for adults. You can do it.
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post #74 of 95 (permalink) Old 06-20-2019, 12:23 PM
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Quote:
Originally Posted by bcsman View Post
If I was younger I'm sure these new adventures would not slow me down or stop me from engaging. I'll bet most of the veterans here started out at a younger age so now it seems like nothing to split, tear down, and repair, do it with your eyes closed. But at my age and lack of mechanical experience it seems like a larger hill to climb so don't think too much less of me for going the route I am. I WILL get things fixed and the help and enthusiasm I get here helps immensely. Many thanks for patience and advise!!!!
I started doing this kinda work when I was in my early 30's, I am now 55 yrs old ( sigh..lol ). yes..i have years of skill on doing what I do, but !!. you will never get to where me and others are...IF YOU KEEP DOUBTING YOURSELF !. just break out the service manual, some good basic tools...and GET-R-DONE !.
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post #75 of 95 (permalink) Old 06-20-2019, 12:45 PM
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and don;t forget if you run into troubles,lots of GOOD folks here with skills willing to help you get thru them!
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post #76 of 95 (permalink) Old 06-20-2019, 01:19 PM Thread Starter
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I can't reply to all these kind and positive words but very much appreciate them!! I got my new Wiseco piston today and took it over to the shop that has my 2 jugs. Gonna check the removed one first and if out of tolerance they will bore the jug off my spare engine with the 1mm oversize piston. I have the head torn apart and ordering new valves and valve parts. I have the engine ready to pull, just need my son to help get it out, then will start taking off front and rear covers and the parts needed to install on the bottom core I'm getting. I will clean all those parts, I have already done most of those before except for the gearshift linkage. It will be much easier this time as when I did my timing the engine was installed.


Think I will put my newer cam sprocket and chain on this bottom core, altho it does come with those. Hopefully I will have things going soon. Then when time is available I will tackle the crank issue and whatever needs replaced on my bottom core. It will prolly take a little time as most of you said on your first teat down. Again the gears are going to be the biggest challenge, but already have those pages printed from the SM.


Prolly end up opening a small engine repair business after this.....maybe not


And by the way gonna be 67 next week...sigh...

1998 Honda Foreman 450ES

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post #77 of 95 (permalink) Old 06-20-2019, 05:43 PM
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Originally Posted by bcsman View Post
I can't reply to all these kind and positive words but very much appreciate them!! I got my new Wiseco piston today and took it over to the shop that has my 2 jugs. Gonna check the removed one first and if out of tolerance they will bore the jug off my spare engine with the 1mm oversize piston. I have the head torn apart and ordering new valves and valve parts. I have the engine ready to pull, just need my son to help get it out, then will start taking off front and rear covers and the parts needed to install on the bottom core I'm getting. I will clean all those parts, I have already done most of those before except for the gearshift linkage. It will be much easier this time as when I did my timing the engine was installed.


Think I will put my newer cam sprocket and chain on this bottom core, altho it does come with those. Hopefully I will have things going soon. Then when time is available I will tackle the crank issue and whatever needs replaced on my bottom core. It will prolly take a little time as most of you said on your first teat down. Again the gears are going to be the biggest challenge, but already have those pages printed from the SM.


Prolly end up opening a small engine repair business after this.....maybe not


And by the way gonna be 67 next week...sigh...
just remember....YOUR NEVER TOO OLD TO LEARN NEW STUFF !.
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post #78 of 95 (permalink) Old 06-20-2019, 06:29 PM Thread Starter
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Proving that everyday my friend...

1998 Honda Foreman 450ES
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post #79 of 95 (permalink) Old 06-21-2019, 01:16 PM Thread Starter
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There engine pulled out and on the bench, little challenge. Prolly a better way to remove, jacked up to help clear and tilted to the left to get the head posts under the frame. Then kinda rolled out taking care not to knock the shift motor. Looks like however you do this it is a pretty tight fit....

1998 Honda Foreman 450ES
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post #80 of 95 (permalink) Old 06-21-2019, 01:22 PM
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Originally Posted by bcsman View Post
There engine pulled out and on the bench, little challenge. Prolly a better way to remove, jacked up to help clear and tilted to the left to get the head posts under the frame. Then kinda rolled out taking care not to knock the shift motor. Looks like however you do this it is a pretty tight fit....
I normally lift the motor up, tilt to the right almost side ways, then edge the motor out the left with the bottom first, just enough coming out to get the top end to clear the frame, then straighten the motor back up, let it rest on the foot rest, then catch my breath, take a pain pill ( just kidding !..lol ), then lift the motor down to floor or bench depending on where I am going with it ? :-). there is a video on youtube from honda plant, they show how they do it like this, but they cheat...they got a hoist !..lol.
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