1978 Honda ATC 90 Full Restoration - Part 5

Welcome to episode 5 and i hope you are sitting comfortably as is a BIG ONE!

So in this episode i am concentrating on rebuilding the engine back to factory spec and aiming to restore it back to full compression or higher. So the first thing on my to do list was to press new transmission bearings into the crank cases, Once those were pressed in i set about removing the main bearings from the crank this done using a little heat and a specialist bearing puller, after the bearings were pulled the crank and con rod were given a thorough inspection and i found no wear so i could proceed with pressing on a new pair of SKF bearings.

I then started to refit the crank and transmission back into the cases and joined the two halves with new gaskets and a nice smear or blue hylomar to ensure a good seal and no leaks. Once joined the screws were torqued up to the correct torque to ensure proper bearing wear and stress loading.

Then came the fitting of the oil pump which was inspected and rebuilt with all new gaskets and seals. I then installed the gear selector rod and index cam and arm and torqued them to the correct torque value. Next came the fitting of the flywheel and clutch assembly this was simple enough as they are on splined shafts and held be a snap ring and castle nut which i used a special socket to tighten up properly then the bearing cap and new bearing was fitted to the clutch assembly then that was all sealed away with a new gasket and side casing.

Next it was time to remove the old piston and fit a new old stock piston and rings. this was a very simple job consisting of pushing the gudgeon pin out,removing the piston and then simply doing the reverse with the new piston making sure that when fitting the rings they are at least 120 degrees apart from each other to prevent blowby.

I then gave the cylinder a quick hone to restore the crosshatching and remove all the glazing from many hours of previous use. Once honed and cleaned it was ready for fitting, not rocket science compress the rings and slide the cylinder bore over the piston and knock it down onto the dowels.

It was now time to strip the cylinder head down to inspect the valves and their seats and im really glad i did as they were in severe need of re-lapping especially the exhaust valve, once lapped and cleaned it was ready for new oil seals and re-assembly. Again nice and simple slide it over the head studs and torque it down with new nuts and washers ensuring the dome nut is on the correct stud!

After that it was a case of making sure the piston was at TCD ( top dead centre ) and installing the camshaft and tensioning the cam chain Once done the engine was now safe and i could proceed to build the rest up with very little hassle, auto advance, points, rotor , stator and the high and low gearbox.

All i had to do then was set the tappets clearance and fit the covers and the nice new Honda decal and i was all ready for the compression test. Last time the engine barely managed 78PSI and im very happy to say that this time we are up at 130/140 PSI.

So all the engine work has been a tremendous success and i really cant wait to hear it running

I hope you will all join me again soon and I also hope you enjoyed the video

Stay Tuned and i will see you all again soon.

RRC
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RRC Restoration

1978 Honda ATC 90 Full Restoration - Part 5

Видео 1978 Honda ATC 90 Full Restoration - Part 5 канала RRC Restoration