I've finally received the top end gasket set from ebay. If time permits, I will start putting it all back together over the weekend. I'll keep this thread going to post my progress and to post pictures with as much write up as I can.

 

Glad to hear you finally got your gasket set !!! 10/10 for keepin your cool mate. Let us know how you get on , will be interested in any pics you may have and good luck with the rebuild.

 

sounds good. got mine tuned in finaly i think havent been able to take it for a short test burn on account of the weather but felt and sounded great the last time i started it to sync the carbs

 

Day 1

1) Took all the fairings and gas tank off. Also removed the 3 remainig original pistons and had a really good look at the #2 connecting rod (that's the cylinder that was damaged by the broken valve) and no damamged/bend is visible. Looks good to me!

2) The remining original pistons. The intake valves clearly made contact with the pistons but it was a slight contact. Not enough to cause any damage to the rest of the rotating assembly.

3) The replacement pistons all lined up. Cylinder # 1 on the left.

4) Another angle of the engine fully diassambled.

5) The new top end gasket set and the old base gasket.

 

6) # 2 & 3 pistons are in.

7) All four pistons are in and so is the new base gasket.

8) This is how far I got in 3 hrs.....day one of asembly is done. Took a bit to get all the pistons to slide into the cylinders, but after 20 min, they were all in. Whoo hoo!
"Special Honda tool" my foot...... an ice pick and time works just as well.


Day 2

9) The replacement cylinder head, the new head gasket is on and so is the lower timing chain tensioner. It was a short evening.

 

right on!! you are getting there, keep us posted!!

 

Had a little time today to work on the bike.

Finally the head bolts are torques down to 33ft/lb, cams are timed and set too.
The second picture is from a different angle of the progress. The carburators and exhaust pipes are next in line. I'm a bit busy fixing my spare car so the bike must wait till the weekend.

 

Hey Imo000, did you have any problems with putting the cams back in? (can't get mine back in)

 

The previous owner's mechaing took the intake cam sprocket off and that's how I instaleed it. The sprocket was loose on the cam, then when the chain is on the sprocket, you pull on it (to let the tensioner give more slack). and this is when you slide the sprocket back onto the cam. Tighten down on bolt and then, by hand, turn the engine over, so you can have access to the other bolt.

If you keep the sprocket on the cam, the chain will be too tight to go back into it's spot.