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bigredmark

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Reply with quote  #1 
The compression was a little low on the 1982 Honda 200E so it was time for a rebuild. The leakdown test pointed me to the cylinder/piston/ rings and not the valves. Here are the links to the compression test and the leakdown test.

Compression test

Leakdown test

The motor has been removed for the restoration which is required to disassemble the top end. Here are some pics and captions of the disassembly.

IMG_7285.JPG 

Motor on workbench. I cleaned it first to avoid getting dirt into the motor.

IMG_7286.JPG  IMG_7287.JPG 

Remove pulse generator and cam sprocket.

IMG_7288.JPG 
Using a micrometer to measure the camshaft. the service manual has the design and service limits listed in it. You can also check the specs listed on justbigreds.com by clicking here.

IMG_7290.JPG  Rocker cover removed.


IMG_7295.JPG  Cylinder removed.

IMG_7297.JPG 
Piston and cylinder dimensions are ok. Honed cylinder to seat new piston rings.

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bigredmark

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IMG_7326.JPG 
Checking piston ring end gap using feeler gauges


IMG_7330.JPG 

Installed piston on connecting rod and piston rings


IMG_7331.JPG 

Installed cylinder

IMG_7333.JPG 

Using valve spring compressor to remove valves


IMG_7337.JPG 

I removed the valves to inspect them and to replace the valve seals which were included in the top end gasket set.

IMG_7338.JPG 

New valve stem seals installed

IMG_7339.JPG 

cylinder head cleaned, inspected, reassembeled and ready to install.
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bigredmark

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Back on the motor. Put the cylinder head, rocker cover, and pulse generator back together. Now I just have to set the valve clearance and the motor is ready for cleaning, priming and painting.

   
IMG_7341.JPG 
cylinder head and rocker cover installed
  IMG_7342.JPG 
cam and camchain sprocket installed.

IMG_7343.JPG 
Pulse generator installed. Set air gap. Spec is .015" to .025".
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