My first rebuild to 416

[sideways]

so i've owned this bike since 2002, and had someone else rebuild the top end once since i bought it. i noticed some bad smoking/oil loss end of last summer. didnt have the time or money to do it over the winter, so im doing it now.

I've already done rear swingarm bearings, rear carrier bearings, front shock rebuild, a-arm bearings, linkage bearings.

This is the first time i've done a top end rebuild, so if there are any good tips you can give me, please do.
i got the tear down done easy enough, but i fear its putting it back together thats the tough part.

I am going with a wiseco 10:1 87mm (416) piston kit, stage 1 cam, stock cam chain, and the obvious new gasket kit. anything else i should do while its apart?

here are some pics of before and what it looks like tonight

is this residue normal for a 3 year old piston? what is it?
http://i301.photobucket.com/albums/nn77/prfakaharry/IMG_0251.jpg
not sure if you can see the lines in the piston wall, is that scarring?
http://i301.photobucket.com/albums/nn77/prfakaharry/IMG_0252.jpg
http://i301.photobucket.com/albums/nn77/prfakaharry/IMG_0253.jpg
http://i301.photobucket.com/albums/nn77/prfakaharry/IMG_0254.jpg
http://i301.photobucket.com/albums/nn77/prfakaharry/IMG_0255.jpg
http://i301.photobucket.com/albums/nn77/prfakaharry/IMG_0256.jpg
http://i301.photobucket.com/albums/nn77/prfakaharry/IMG_0257.jpg
before picture. the after picture shouldnt look much different tho, just doing motor work, no plastics or anything else.

so i have a ton of questions about this, you'll be hearing from me again soon.

[mitchamus]

How do you like those fox shocks? Im about to order a set for myself..

[sideways]

love the fox shocks. great adjustability for any type of riding you'll do. my only concern is they heat up pretty good after a long ride, expanding the air in them. so you have to set them a few psi lower to accomodate. maybe thats why they made the evol's with the piggyback to disperse heat better.

[Honda#4]

The stuff on the piston looks normal anyway thats how mine looked. You should have cleaned that quad alot more than that, getting dirt in a motor is not a good sign.

[BigBore24]

yah the carbon buildup is normal, cylinder doesnt look too bad either. you should have no problems with just having it bored and honed to fit the new piston. i agree with honda4, with all the plastics off i would have power washed the crap out of that thing before opening the motor up. you still could wash it realy good after you get the motor back together, just dont forget to change your oil

[mcwilly]

Is that a real tap on the wall? I mean, I know it's real...but does it really work?

[mitchamus]

Originally posted by mcwilly
Is that a real tap on the wall? I mean, I know it's real...but does it really work?

I seen all the cans and bottles but totally missed the tap. i guess he spends alot of time in there. lol

[sideways]

like my Wallerator? (kegerator) tap actually works, with full co2 and nitrogen hookups for both regular beer and stouts (I.E guiness)
i dont have much to say about the cans, that collection took a lot of work.

ok so clean it a lot better BEFORE taking it apart next time, now that i think about it, makes sense.

i was planning on cleaning the rest of the bike while the top end was being bored and honed. theres a 2 week wait. i am using simple green and a dish brush to clean it. the electrical and air box are off, for easy cleaning.
i put a plactic bag over the hole into the cases and kinda bolted it down to prevent dirt entry. also wrapped the carb to prevent anything from getting in there.

http://i301.photobucket.com/albums/nn77/prfakaharry/atv/IMG_0262.jpg
http://i301.photobucket.com/albums/nn77/prfakaharry/atv/IMG_0263.jpg

[sideways]

I cleaned the best that i could, except the top of the case, gonna leave the rest until i get the motor back together, then I'll power wash it down nice and clean.

so if some dirt did get into the engine, the best thing to do is change the oil and filter? or is there something i can do to flush out the bottom end?

whats the best thing to use to scrape the old gaskets off? single edged razor blade, dremel, sandpaper?

I am starting to collect the things i will need to put the motor back together. Does anyone have some good suggestions for assembly lube? Is there a gasket sealer i should use when i put the engine back together? I am using the honda service manual as my guide.

sorry about the questions, but it is my first time building anything on a motor, so i am a little nervous about this. knowing my luck, it'll never run right again.
me doing the work is to save some money, i usually have a honda mechanic do these things. being a self employed contractor is tough right now.

[Honda#4]

I used a putty knife for scraping the old gaskets off just becareful not to drop that stuff in the bottom end. For assembly lube Bel-ray makes good lube. I used RTV silcon gasket maker and used very little just so my gaskets stick to the metal.