Mine 700 has got a slow weep too in about the same place. Nothing serious, but I might lock you in my garage with three days worth of sandwiches, refreshments, and a camera, and let you "have fun" :) Great job.
-Kyle On Tue, Aug 10, 2010 at 11:09 PM, Matt <[email protected]> wrote: > Tonight I was finally forced to clear the memory of this camera I > borrowed (finally found mine buried on my desk) and when sifting > through the photos I came across a few I thought you guys (and gals) > might like. These are of some "light maintenance" that I preformed a > month or two ago on my 450. If you were ever curious what the inside > of a 450 motor looks like wonder no more! > > http://www.mediafire.com/imgbnc.php/5b1214f349a43f72966998dcc2a769a46g.jpg > > Looks so empty doesn't it? I decided to preform this procedure > because I had noticed I'd been loosing oil at an increased rate. I > had lost a full quart (or whatever the full length of the dipstick > marking means) in about 300 miles. What's worse is the leak was > coming from the edge between the lower and upper crankcase and dumping > oil right onto my back tire. Though I hadn't felt anything squirrley > I really didn't feel comfortable riding it this way and I had the next > two days off so seeing little choice I dug in. > > http://www.mediafire.com/imgbnc.php/095d5a9ba47eec92f53ba916905173166g.jpg > > The problem became redily apparent as soon as I got the motor out. > The two halves are sealed by Honda's version of RTV and the years had > given it more in common with rock than rubber. Heh it's still got the > factory grease pencil numbers on the cases, I didn't notice that when > I took this picture. The extraction itself was surprisingly easy and > the motor started flying apart as well. > > http://www.mediafire.com/imgbnc.php/d1151a6045434e0f9c010d051737b87b6g.jpg > > A slight snag was removing the clutch basket which requires a single > use tool from the dealer for God knows how much. I just ground an old > wrench til it fit then turned it with a crescent wrench and a piece of > pipe. Someone else in the group has ground a better tool out of black > iron pipe. The big problem I ran into is that to separate the two > case halves nearly every component under the side covers must be > removed. This includes the stator which resides under the flywheel > and since I didn't have a puller I called it a night and stopped here. > > http://www.mediafire.com/imgbnc.php/c253a47a2b60de4ceaa02c0c9f5fdcbf6g.jpg > > Next morning I called around and found a little hole in the wall bike > shop that carried the required tool. In the photo you can see my > meticulous and well documented parts layout carefully designed so that > nothing is misplaced during reassembly :) Yeah I'm not sure how it > still runs either. You can also see another tool I made (angle iron > with a sprocket bolted to it) to hold the transmission shaft in place > to remove the clutch basket. > > http://www.mediafire.com/imgbnc.php/64772ea1ac46090c416e3ffdd40f55396g.jpg > > A quick turn of the wrench, three screws and a little prying later and > POP! Not bad, little gunk on the pickup screen but nothing serious. > Those two orings are the oil passages two the oil filter cradle in the > lower case. The aluminum casting just south of that is where the oil > pump bolts up. It's a little hard to see but where as there is still > RTV on the side closest to the camera it's been mostly blown away back > by the counter-shaft. > > http://www.mediafire.com/imgbnc.php/9304d48f6bada601cefa5e875b2860d26g.jpg > http://www.mediafire.com/imgbnc.php/a82ffcf10704a6e638a26deae1a606076g.jpg > > After spending an hour playing with the transmission (those things are > so cool) I cleaned everything off and applied a thin layer of RTV to > every machined surface along the rim. It's important to make the > layer as thin as possible otherwise small beads or RTV can end up > clogging the pickup screen or worse... I was also careful to reapply > RTV to the transmission out and flywheel seals into the cases. > > http://www.mediafire.com/imgbnc.php/fa94c8eb371f34e5b445ce28f6f767ae6g.jpg > > Reassembly went smoothly and this picture was taken about 8pm. About > 10 minutes later I go to pop it into neutral to reinstall the chain > and it won't get out of first. With a heavy heart I took the motor > back out and called it a night. After work the next day it came ALL > back apart and I tried to figure out what I'd missed. Playing with > the transmission yielded that the gear indicator was causing it to > bind as it went over the neutral lobe. A quick check of the manual > revealed a washer had been forgotten under the gear indicator causing > it to sit just low enough to bind. Remind me why I did this again? > About midnight it was back in the bike and I had primed the oiling > system. I had it buttoned the rest of the way up 3 hours after work > the next day and low and behold no more leak! So about 30 hours of > work to fix an oil leak.... Perhaps I'm not all there and the fact > that I still had fun doing all of that is probably a bad sign. Oh > well :) > > Ride safe and wrench hard, > > Matt > > -- > You received this message because you are subscribed to the Google Groups > "Nighthawk Motorcycle Lovers!" group. > To post to this group, send email to [email protected]. > To unsubscribe from this group, send email to > [email protected]<nighthawk_lovers%[email protected]> > . > For more options, visit this group at > http://groups.google.com/group/nighthawk_lovers?hl=en. > > -- You received this message because you are subscribed to the Google Groups "Nighthawk Motorcycle Lovers!" group. To post to this group, send email to [email protected]. To unsubscribe from this group, send email to [email protected]. For more options, visit this group at http://groups.google.com/group/nighthawk_lovers?hl=en.
