Cb250 Engine Rebuild

[Green199]

Pulled in a favour off of my mate, and getting the cases blasted this friday!

Then want to spray them in a satin/matt black if I can. Anyone have any recommendations on paint?


Got hold of a dremel as well so will do the clutch cover oil mod by Crazypj.

Will then get hold of some hondabond or other sealant, and some engine lube and get the bottom end back together! Cant wait for this now!

 

[Green199]

Did the crazyPj oil mod to the transfer piece.

Started like this,

After grinding down one side,

And after both sides had been done.

I also quickly went over the side cover with a scotchbrite pad. It shined up extremely well! This was after brushing it for literally like 3 minutes.

 

[crazypj]

You did put the clip back on to hold transfer piece in place?

 

[Green199]

You did put the clip back on to hold transfer piece in place?

Yep! Just held it in place for the pic to see if the spring was overlapping. Seemed it did like the one in the thread you made about it.

 

[DesmoBro]

seems to be coming together alright for ya

 

[NeeksRR]

Good stuff, enjoying the read and info. Though, when you got the 1mm overbore and pistons, where did you find the proper head gasket for that size? Ive been looking into a 2 over on mine, but cant find anything but and OEM gasket kit.

 

[Sonreir]

http://www.coppergaskets.us/

 

[NeeksRR]

http://www.coppergaskets.us/

*high five*! Thanks man! ;D

 

[Sonreir]

No problem. I definitely don't mind sending Lani some extra business. He's a real stand up guy.

If you're not familiar with how copper gaskets differ from the OEM graphite styles, read up on them. They can be a bit tricky and they're less tolerant of hasty cleaning and assembly.

 

[Green199]

I managed to get access to a blaster, but only blasted my cylinders to get the dirt out of the fins. Everything else was pretty clean so I didn't bother blasting it. I also just helped my mate move into a new workshop for his Motorsport business which he said I can use when I want, so I now have a place to wrench whilst at University.

I cleaned all of my parts off after cleaning and blasting with paint thinners and brake cleaner.

Was just about to hone the cylinders, and bam!...drill burnt out...so getting them honed on wednesday now!

Also picking up some matt black engine paint (not sure on enamel or VHT etc yet) tomorrow morning to paint the cases with when I go back to the shop on wednesday.

 

[Green199]

Had lectures cancelled at uni so I managed to head back to the workshop today.

Picked up some matt black Hammerite BBQ paint on the way to spray my cases with. Please ignore my mate lurking in the background haha

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Only sprayed the top case, camshaft box and the camshaft bearing housing things. The paint went on really well and gave a lovely matt finish which doesnt show up too well in the photos but is excellent! So pleased with it!

Heading back tomorrow to spray the top case, cylinders and hopefully the head.

 

[NeeksRR]

Nice, looks good. Are you planning on clear coating? Im painting the engine now too and Im just curious.

 

[Green199]

Nice, looks good. Are you planning on clear coating? Im painting the engine now too and Im just curious.

Thanks. no cleacoat for me, leaving it as it is.

 

[Green199]

Finished painting all the engine pieces apart from the head (still need to extract a bolt to hold the carb boot on).

Started to assemble the bottom end too.

Put the transmission in.

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Put the crankshaft back in.

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Torqued the carrier down to spec (11.6-15.2 ft lb).

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...and then....


...Fuck. Tightening the case bolts down and I tightened 2 too tight and sheared them clean off. There is about 1mm of exposed stud on one of the fuckers, so I may be able to clean it up and then easy out it. On the other, it is snapped right down in the guide cylinder. I should be able to easy out it. Or I can get to it from the underside as the whole goes the entire way through.

 

[Tim]

Are the ones you sheared off studs? Or were you installing the other 1/2 of the case? Reason I ask is there obviously wasn't any sealant on the cases as its clean in the pic with the sheared bolts.

 

[Green199]

Are the ones you sheared off studs? Or were you installing the other 1/2 of the case? Reason I ask is there obviously wasn't any sealant on the cases as its clean in the pic with the sheared bolts.

They were the bolts for installing the other half of the case. I did have sealant but cleaned it off when I removed the case to get a pic. Either that or it was a pic of before I put the sealant and tried to install them...cant remember haha

 

[Green199]

Boom!

Studs extracted and bottom end sealed up!

Just waiting on my cylinders to be bored and honed and them Im ready to whack it back together!

 

[Green199]

Started to hone my cylinders but only managed one, will finish the other soon.

<img src="http://imageshack.us/a/img839/7557/17022013565.jpg" alt="Image Hosted by ImageShack.us"/>


I then managed to seal the bottom end up, install the clutch with new plates and springs, install the oil filter and put the cases back on.

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The stator wiring was a bit 'beat up' and the neutral light wire was broken, so I removed the horrible plastic covering and will recover/shrink wrap and add new connectors to it tomorrow.

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Ahh....We're getting there....slowly.

 

[Green199]

I managed to put some protective covering over the new stator/neutral wires, and clear shrink wrapped the end. Going to be putting new connectors on the end too.

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I also got to try my hand at some polishing. It isn't great, but it is shiny enough for my liking!

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[Green199]

Well, it has been a while, but engine work finally got carried out!

You can check my build thread for more extensive info etc.

http://www.dotheton.com/forum/index.php?topic=36795.msg570285;topicseen#new

Got my cylinders back from being bored 1mm oversize, and fitted them this afternoon. I needed the head helicoiled as one of the spark plug threads was badly stripped. So the head is going to be cleaned up tomorrow and then fitted. Hopefully will finish the motor up tomorrow too!