honda305.com Forum

A short story.

I torqued the head bolts down, and then tried to turn the engine over. It would turn about 90 degrees and then "THUNK" - hard up against something. I turned it the other direction - "THUNK". Same thing. I rotated the kick start shaft, thinking I had the index on it off when I installed the stopper bolt. "THUNK".

Hmmmm.

I sent a PM to LM, and then talked to him, and he gave me some pointers. I tried them, and "THUNK". So. I removed the clutch and spun the transmission. No binding, no problems, no "THUNK". I tried to spin the crankshaft. "THUNK". Oh, boy. Now, what could this be? I doubt it's the valves, the adjusters are all backed out on the rocker arms. Could a liner be contacting the crankshaft? I don't see how. How about a piston skirt? I don't see how!

I took a few breaths, removed the headbolts, removed the cover and watched the cam as I turned the crank. "THUNK" - and the cam did nothing strange. BUT. The head and barrel were trying to lift from the top case. It seems to me it was doing that before I put the headbolts on. Did I drop a bolt or a nut into one of the cylinders??

I disconnected the cam chain, removed the two 10mm nuts from the studs near the sparkplugs and lifted the head off the barrel. Nothing in the bores but pistons! Hmmmm. I rotated the crankshaft. It turned easily and cleanly. BUT. The pistons were trying to lift the head gasket when they reached the top of their stroke. HMMMMMMMMMM!!! I looked carefully at the head gasket. I then picked up the OTHER head gasket that was in the gasket set and looked at it.

You guessed it. The gasket set had two head gaskets, one for a CB72 and one for a CB77. I didn't realize that, and I grabbed a head gasket and put it on the barrel. Of course it was the CB72 gasket!

All is right with the world now. The correct head gasket is in place and the engine is back together. The crank rotates all the way through it's travel with no noises or binds or anything weird. The transmission does the same. The kick start shaft turns as it should and ratchets properly.

Yay!

I had some chrome bits soaking in oxalic acid solution overnight, and I pulled them out after I was done with the engine. They are GORGEOUS!!! I made a bigger batch of the solution and placed the shock bodies, headers, and rear 1/3 of the mufflers in that. I'll look at them later this morning.

Moral - if you think its not working right - IT ISN'T!

Dear Sarals, I smiled with what you did. We are all only human and we all always learn something new most days. I like the fact that you are so open about what you do and therefore help others. "On Ya" girl. All the best Jerry

jerry wrote:Dear Sarals, I smiled with what you did. We are all only human and we all always learn something new most days. I like the fact that you are so open about what you do and therefore help others. "On Ya" girl. All the best Jerry

Jerry, if anyone is upfront, that would be me! I always subscribed to the "dumb question is the one not asked" rule, and that applies to mistakes, too. Part of my process with this journal/blog is to catalog ALL of what I do, in hopes other folks do get to learn from it.

I thank you!

Dear Sarals, Emo and I spoke about it yesterday. It is not that often that such an open brutally honest with oneself person comes through. I am sure it is a huge benefit with your job as a chopper pilot. All the best Jerry

jerry wrote:Dear Sarals, Emo and I spoke about it yesterday. It is not that often that such an open brutally honest with oneself person comes through. I am sure it is a huge benefit with your job as a chopper pilot. All the best Jerry

Owning my mistakes and learning from them is certainly part of the realm in my line of work.

My best to you, Jerry!

I'm into more small stuff, specifically, electrics.

I'm having trouble finding those fasteners, the soft aluminum "caps" that attach the spark plug leads to the coils. Mine are just totally shot, and they need to be replaced. What have you folks been using for that job?

Also, the rubber stud terminal insulator cups, I guess that's what they're called, that cover the terminals on the coils are both perished. I need to replace them. Does anyone have a source for them, and what are they really called?

Finally, spark plug caps. What is everyone using, in place of the (mismatched) originals (that I have)?

I'm mulling over the idea of the Podtronics "BSA" regulator. I also read where Davo is looking at a John Deere/Kohler regulator rectifier. Any suggestions on these, or will the stock rectifier suffice (the rubber on it has also perished)?

Sara

Not sure about the HT lead "caps", I just bought old coils whenever I could.

As for the rubber "boots" you may be able to get them from a vehicle wiring specialist.. In the UK we have "Vehicle Wiring Products" which sells all sorts of stuff.
http://www.vehicle-wiring-products.eu/V ... mepage.php
http://www.autoelectricsupplies.co.uk/p ... ategory/32
The SuperHawk doesn't really have a regulator so the podtronics part would be an upgrade. It's not really a "regulator" in the modern sense of the word, it just rectifies the AC in to DC then chops off the excess voltage and turns it to heat, just like the Zener diode used to do on Triumphs and BSAs. It does mean that you can simplify the wiring and junk the old Honda Rectifier.

Plug caps. Most people just use modern NGK items unless you want that "original" look.

G