Change damaged pistons during a rebuild.
Rebuilding a Honda GL1100 Engine requires a big deal of mechanical faculty and doctrine. Reassembly requires a big league deal of concentration and some speciality tools. When timing is fix, it must be done equitable, as the 1100 is an interference Engine. Engine damage Testament creature provided you effect matters incorrectly. Bear a Engine album handy and your rebuild can be fortuitous.
Instructions
Engine Disassembly
1. Withdraw oil and coolant from the Engine and discard. Area the motorcycle on its centre stand and remove the engine from the frame. Abode it securely on an engine stand. The engine is enormous, so you Testament probably want an assistant for this course in the method.
2. Disassemble the engine case, starting at the rear of the engine. Remove the vacuum advance mechanism, the mechanical advancer, and the rear engine include. This Testament grant you to deed the camshafts without driving a valve into the piston.4. Remove the front engine comprehend, the camshaft pulleys and the camshafts. Remove the cylinder heads, and locate aside.
3. Remove the coolant tubes, the cylinder belief covers and the timing girdle covers. Turn the Engine to top dead centre (TDC) and site Everyone timing band with an arrow to present progression of rotation. Install the right side pistons and rods in the cylinders they came out of, using the piston ring compressor. To prevent damage to the crankshaft, place small sections of rubber hose over the rod bolts before installation. Install rod caps, and torque to specification. Install left side pistons and rods, ensuring the rods face the proper direction and oil holes line up. Remove the scavenge pump bolt and sprocket and the mechanical advancer manage shaft. Remove the starter also. Sticker all parts and bolts as you remove them and distance them on a barn door Disinfected occupation universe.
Remove the 19 bolts from the left engine circumstances, and the three bolts from the ethical. Rotate the engine so the left side is up. Maneuver the shift arm absent from the shift drum, and partially seperate the instance halves. Operate a couple of two by fours to buttress the upper occasion, and situate shop towels under the pistons, so they Testament not strike the transmission when the left action is removed. Lift off the left engine event.
5. Remove the left and hold together side rods and pistons, using a metal marker to point which cylinder they came from. Remove the crankshaft, and carefully set it aside.
Inspection, Cleaning, and Reassembly
6. Inspect the rods, pistons and crankshaft for wear. Replace any items that do not pass inspection. Using the inside micrometer, inspect the cylinders for out of round and wear. If cylinders are worn, and it is necessary to bore them, purchase new pistons to fit the new bore. Inspect the cylinders for warpage, checking in a criss-cross pattern. If cylinders do not need to be bored, deglaze them using a cylinder hone.
7. Use a dial indicator to check the crankshaft for taper and out-of-round. Temporarily reinstall the crankshaft, and use plastigauge to determine if bearings need to be replaced. If they do, consult the manual for bearing selection, and purchase new bearings. Using a piston, push a piston ring into the cylinder. Inspect the end gap, and if it does not fall within service limits, replace the piston rings.
8. Clean all parts thoroughly if they are to be reused. As new items are placed on the work surface, throw away old items, or set them aside elsewhere so that they are not accidentally reused. Lay out all tools you will need, and ensure that they are clean before beginning reassembly.
9. Install the crankshaft. Stagger piston ring gaps 120 degrees apart. Coat pistons and rings with a thin coat of oil before reinstalling. Besides location the belts with a R and an L to denote which side they came from. Loosen the region tensioner bolts, and modification them elsewhere from the belts, then retighten the bolts. Remove the belts, using caution not to receive oil on the belts or they Testament call for to be replaced. Rotate the crankshaft 90 degrees either line from top dead centre. Reinstall the left engine case, using the case support and piston bases. Apply sealant to the case halves, remove the piston bases and case supports, and seat the cases together. Tighten bolts to correct torque specifications.
10. Continue reassembly in the reverse order of disassembly. Using the torque wrench, torque all bolts to the proper specification. Use new gaskets and o-rings to ensure there are no leaks. Follow all steps in the manual regarding timing belt installation, as improper timing will cause severe engine damage. Reinstall the engine in the frame. Run the engine, and inspect for leaks.
