28k mile input shaft
28k mile clutch hub
new clutch hub
23k miles later...
51k mile input shaft
note Honda moly 60 lube everywhere
happy intake valves! :)
unhappy exhaust valves :(
Hmm.. clutch housing looks warped
refacing an exhaust valve
much better
pressure plate warped
pressure plate de-warped
carbon after cooking with a cutting torch
happy exhaust valves! :)
baking soda blasted and washed
waiting for new rings
Hmm... 0.009" runout...
Yay! The crank flange is straight!
tooling marks on the shift star
tooling marks polished away
shiny shifty bits
polished the shift fork shafts and shift arm
also retensioned the follower arm spring
de-wobbling the clutch housing mounts on the flywheel
test indicator stand attached to crankshaft flange
front transmission case installed,
test indicator zeroed at 12 o'clock on
the input shaft front bearing bore
crank spun 90 degrees counterclockwise
the bearing bore is 0.0050" closer
to the crank centerline at 9 o'clock
crank spun another 90 degrees... 0.0100" closer
to the crank centerline at 6 o'clock
crank spun another 90 degrees... 0.0035" closer
to the crank centerline at 3 o'clock
Back to zero at 12 o'clock, so you know
nothing slipped. The input shaft rides
0.0050" high and 0.00075" to the right
in relation to the crankshaft.
centering off the dowel pin bore
dowel bore in front case bored offset
0.0055" and oversize from 13.52mm to 14.90mm,
15.00mm OD bushing fabbed up, press fit
and Loctite 640 to hold it in place
bushing pressed in place, boring inside
diameter to 13.52mm
both dowel bores offset and bushed to size
closer shot...
and closer...
zeroed at 12 o'clock
-0.0009" at 9 o'clock
-0.0006" at 6 o'clock
-0.0001" at 3 o'clock
back to zero at 12 o'clock
input shaft is 0.0004" to the left of
and 0.0003" under the crankshaft
Flywheel and clutch mounted to a VW Golf
crankshaft for spin balancing. (I didn't feel
like taking the crank out of the bike...)
spin test
left piston is 426.5g
right piston is 424.2g
baby gots junk in the trunk
"Get me a beer while you're up!"
losing weight is hard
424.7g... half a gram tolerance it is
popped the seals off the bearings...
not much grease left in there
that's better :)
good as new(ish) ;)
new splines vs. old splines
all the bits are cleaned up and ready to go
so shiny!
front case took a detour through the oven
for a bit so I could slip the bearings into place
rear case visited the oven too
all buttoned up
hey, what's this extra gear I have left over...
ah, probably don't need it *toss*
prepping the valve seats
with a wee bit of port work
just a light swipe with the die grinder...
manual says "always install right cylinder first"
okay, sure... piston and cylinder installed
head all clean and spiffy, ready to go
almost done, valve gear installed and
verifying accuracy of TDC mark on flywheel