DohcBikes
10-30-2014, 03:19 PM
This thread is purely for my own therapy after a mind bender this morning.
At my shop I rebuild all the three wheelers because my boss knows I love them. A customer brought in an 84 200x that had sat for years because he needs a deer blind bike. I got it running right away but it filled the shop with smoke instantly and never stopped smoking, so the boss had me rebuild it.
Good thing because both inner valve springs were broke. So I got my parts, new piston, rings, valves, springs, gaskets blah blah etc. And a brand new cam chain.
I bored and honed the jug, lapped the valves and rebuilt the head, then assembled it, cam timing on as always, tensioner adjusted, tappets in spec. For some reason I couldn't quite get the ignition timing to line up how it always does,,,my advancer had to be way to the left to be even close. Check cam timing again, it's on. Right?
So the bike started in 3 kicks. Sounds goodish right off the bat, no smoke, just a bit more clatter than I like to hear in a new motor. Sometimes on the 200x Cam chain tensioner you gotta stick a pick in there and pull up on it a bit to get better tension, but that did nothing to quiet it. Checked the valve lash again, good to go.
Eric, the boss and I can all hear this Damn thing slapping in there. I have built several engines for Wayne now so he knows I did it right. Right? Ughhh.
Since he trust my ability to assemble an engine he says to pull the flywheel again and see what the tensioner assembly looks like. Ok, pulled the flywheel.
Released the tension on the chain, and it was so loose that a link doubled over on itself from the slack. Dat Shlt ain't right. New chain though.
This cheap piece of $!#@in &#!$ was built so terribly that in 100 links, it was about 1/8 inch LONGER than the used chain Eric dug up to compare. Just long enough that the tensioner just couldn't quite do its job, and just long enough to also make it look like one tooth off was correct timing, which explained immediately why I couldn't get the advancer timed just right. Son of a &!'@#.
All is well, the bike runs perfect, and no Hondas were hurt in the making of this thread.
Moral of the story is don't always trust your brand new parts.
Ahhh I feel so much better now, thanks for reading.
I think some after lunch wheelies are in order, maybe I'll grab some action shots to add some excitement to the thread after work.
At my shop I rebuild all the three wheelers because my boss knows I love them. A customer brought in an 84 200x that had sat for years because he needs a deer blind bike. I got it running right away but it filled the shop with smoke instantly and never stopped smoking, so the boss had me rebuild it.
Good thing because both inner valve springs were broke. So I got my parts, new piston, rings, valves, springs, gaskets blah blah etc. And a brand new cam chain.
I bored and honed the jug, lapped the valves and rebuilt the head, then assembled it, cam timing on as always, tensioner adjusted, tappets in spec. For some reason I couldn't quite get the ignition timing to line up how it always does,,,my advancer had to be way to the left to be even close. Check cam timing again, it's on. Right?
So the bike started in 3 kicks. Sounds goodish right off the bat, no smoke, just a bit more clatter than I like to hear in a new motor. Sometimes on the 200x Cam chain tensioner you gotta stick a pick in there and pull up on it a bit to get better tension, but that did nothing to quiet it. Checked the valve lash again, good to go.
Eric, the boss and I can all hear this Damn thing slapping in there. I have built several engines for Wayne now so he knows I did it right. Right? Ughhh.
Since he trust my ability to assemble an engine he says to pull the flywheel again and see what the tensioner assembly looks like. Ok, pulled the flywheel.
Released the tension on the chain, and it was so loose that a link doubled over on itself from the slack. Dat Shlt ain't right. New chain though.
This cheap piece of $!#@in &#!$ was built so terribly that in 100 links, it was about 1/8 inch LONGER than the used chain Eric dug up to compare. Just long enough that the tensioner just couldn't quite do its job, and just long enough to also make it look like one tooth off was correct timing, which explained immediately why I couldn't get the advancer timed just right. Son of a &!'@#.
All is well, the bike runs perfect, and no Hondas were hurt in the making of this thread.
Moral of the story is don't always trust your brand new parts.
Ahhh I feel so much better now, thanks for reading.
I think some after lunch wheelies are in order, maybe I'll grab some action shots to add some excitement to the thread after work.