Replated Barrel and piston arrived today, Gasket's coming tommorrow... So I am gonna bolt her up.
Previous experience has scolded me that simply dropping another piston in isent gonna fix things on this bike -
so I intend to rejet over rich, lose the auto lube and fit a fan to eliminate as much margin for error as I can.
at least till things are running smooth.

I had a horrific thought when I was thinking what could be making it run lean and overheat.
After the first seizure - I was was having difficulty splitting the crankcase so got a local Honda
dealer to do it and told them to replace the main bearings while they were there anyway...
I just had this awful feeling like what if diden't seal the crank case right or they missed out one of the seals..
Is the dry seal magneto side accessible? I.e is it inside or outside the crank case, I cant remember....
It had 2 seizures since then each with circa 15 miles on the clock. I can't take any chances this time.

Is there any way I can test any of these theorys without a leakdown tester? I could baby powder some parts
but I imagine things like bottom of the crank case aint going to be easy. If not, does any one have a
leakdown tester they could kindly loan me for a day, If I sorted out the postage fees?

Now I am even more worried.....
I was just looking in my parts box to get my jets ready for tommorow and I came across a brand new bagged seal.
Part number 91201-KAE-003 please tell me it isent a crank seal? my part numbers book is at my brothers could
someone please check for me. I'm confused to why I have it...

scrubs wrote:Now I am even more worried.....
I was just looking in my parts box to get my jets ready for tommorow and I came across a brand new bagged seal.
Part number 91201-KAE-003 please tell me it isent a crank seal? my part numbers book is at my brothers could
someone please check for me. I'm confused to why I have it...

balancer shaft oil seal - sits on the counterweight end of the shaft next to the needle bearing

Cheers skid, from memory I think (hope I ordered two of them) I hope its just a spar. will find out later.

Flywheel side Crank seal appears intact. There is however a fair amount of coolant in my combustion chamber....
Maybe the head gasket gave way when it over heated? could it be something more sinister?

How do I go about getting the coolant out of the combustion chamber without splitting the cases
any ideas apart from turning the bike upside down? I thought of trying to suckit out with clear tubing
but have non to hand - I am unsure of how much is in there but it coats the crank wheel everytime I spin it.

Definitly coolant - i tasted it

ahh well... I turned it on its head and got some out.. I was gonna start a new thread on this but did you know - unless I am missing something -
there is no adjustable needle in the AR carb? I assume you have to buy new needles or maybe bodge a small spacer in there to richen it?

Just spoke to LT they said there should be a clip - but I told him there was non I could see.. he went to check
and confirmed the needle on the AR is not adjustable.. said he dident realise himself al these years either.
I am gonna put a small washer in there to richen it instead.

sorry I know this is turning into a one man rant

However.. How important are the sleeves that sit on top of the barrel studs?
I noticed I am missing two on one side. If it is castrophic to leave them off
I'll call it a day and order some more..

you should only have two. Jon

Cheers Jon,

Magic. Just being extra careful!

Have you already, or are you going to hone the re-bored barrel and piston, ask the firm that carried out the work if this is something they would recommend.
What honing does is put a series of cork screw like, shallow scratches in the barrel and on the piston.
The theory is that these hold on to some off the lubrication, thus easing the friction during the critical running in time.
Good like
Mike

Cheers mike, Yeah got it replated and honed by Stan Stephens. Got her all buttoned up now.
just got to replace the fluids, not gonna be able to do that until a couple of days - which I don't mind as
it will give me some time to run some pre-flight checks. How many mm would you say each clip position
was? I am just trying to fathom what width spacer to use for the carb needle.

My mincers are absolutely rubbish now, but I would say the ridge between each section is barely more than 1.5/2mm .
You could, richen up the pilot circuit, and restrict the air box with some foam, as an alternative.
Mike