Pulled the stator and found this

Dick Eastman · Post by **Dick Eastman** » Sat Nov 28, 2015 7:45 am

LOUD MOUSE wrote:I just noticed that the pin may be HOLLOW.
If I'm correct it is the wrong diameter at the bearing case and that's what pushed it through the case.
Maybe I'm wrong as to the pin being hollow?????????????????????. ..........lm

The pin looks like a 6mm, and it is not hollow; it will rotate, but not move up and down. The hole in the engine case is about .050" deeper than the pin. I don't think the hole is damaged any, because the pin rotates like a nice slip-fit would.
I just put some calipers on the plug, and it is approx. 7mm - it may be a step pin, Tom.

LOUD MOUSE · Post by **LOUD MOUSE** » Sat Nov 28, 2015 7:54 am

If it isn't hollow it is a step pin and wasn't in the bearing case hole when the cases were assembled.
If it was it wouldn't have pushed out the case. (unless it's the wrong pin or upside down.)
Do you have a engine that's apart?
BTW HONDA changed the diameter of the hole in the bearing case and pin near the end of production. .................lm

Dick Eastman wrote:
LOUD MOUSE wrote:I just noticed that the pin may be HOLLOW.
If I'm correct it is the wrong diameter at the bearing case and that's what pushed it through the case.
Maybe I'm wrong as to the pin being hollow?????????????????????. ..........lm

The pin looks like a 6mm, and it is not hollow; it will rotate, but not move up and down. The hole in the engine case is about .050" deeper than the pin. I don't think the hole is damaged any, because the pin rotates like a nice slip-fit would.
I just put some calipers on the plug, and it is approx. 7mm - it may be a step pin, Tom.

Dick Eastman · Post by **Dick Eastman** » Sat Nov 28, 2015 10:36 am

LOUD MOUSE wrote:If it isn't hollow it is a step pin and wasn't in the bearing case hole when the cases were assembled.
If it was it wouldn't have pushed out the case. (unless it's the wrong pin or upside down.)
Do you have a engine that's apart?
BTW HONDA changed the diameter of the hole in the bearing case and pin near the end of production. .................lm

There was what looks like a "ball of aluminum" in the bottom of the hole, and about 3/16" diameter, kind of like weld splatter. It would appear that it fell into the locator pin hole, and went unnoticed when the crank ass'y was dropped in. It would be my guess that when the bottom case was torqued down, the "ball" was compressed at the bottom of the hole by the pin, and popped out the case casting directly beneath it. Then, when the prev. owner flipped it over, saw the damage, he filled that area with some sort of "liquid aluminum" filler. After removing the stator/rotor, I saw the repair, and picked at it with an exacto knife, and the filler/ball came right out as one. I picked at it because there was oil around this "repair".
No, I don't have the cases apart yet, and I think the integrity of the hole remains. Like you said, JB or similar will correct this - I just want to be sure I don't epoxy the pin fast; maybe use a dummy 7mm pin, with release agent on the end when I epoxy the damage. I can then extract the dummy pin and install the factory pin.

LOUD MOUSE · Post by **LOUD MOUSE** » Sat Nov 28, 2015 10:38 am

Let us know how it works out. ..............lm

Dick Eastman wrote:
LOUD MOUSE wrote:If it isn't hollow it is a step pin and wasn't in the bearing case hole when the cases were assembled.
If it was it wouldn't have pushed out the case. (unless it's the wrong pin or upside down.)
Do you have a engine that's apart?
BTW HONDA changed the diameter of the hole in the bearing case and pin near the end of production. .................lm

There was what looks like a "ball of aluminum" in the bottom of the hole, and about 3/16" diameter, kind of like weld splatter. It would appear that it fell into the locator pin hole, and went unnoticed when the crank ass'y was dropped in. It would be my guess that when the bottom case was torqued down, the "ball" was compressed at the bottom of the hole by the pin, and popped out the case casting directly beneath it. Then, when the prev. owner flipped it over, saw the damage, he filled that area with some sort of "liquid aluminum" filler. After removing the stator/rotor, I saw the repair, and picked at it with an exacto knife, and the filler/ball came right out as one. I picked at it because there was oil around this "repair".
No, I don't have the cases apart yet, and I think the integrity of the hole remains. Like you said, JB or similar will correct this - I just want to be sure I don't epoxy the pin fast; maybe use a dummy 7mm pin, with release agent on the end when I epoxy the damage. I can then extract the dummy pin and install the factory pin.

Dick Eastman · Post by **Dick Eastman** » Sat Nov 28, 2015 3:36 pm

I'll have a lot to go over - I went to loosen the LH nut on the cam before removing chain, and was not much more than finger tight; the cam chain had two master links... just a few things. Shifting forks burned - probably the excess end play in the drum from the inverted fixing plate. First gear bronze bush needs replaced; kick spindle bush shot, as well as the end of the kick start shaft that fits this; second gear dogs worn; second and third gears w/ fork grooves correspondingly burned....
I almost think it may be cheaper to find a low mileage tranny set than to try to replace individual pcs - the counter shaft where the sprocket affixes has some wear due to the sprocket fixing plate wearing and allowing the sprocket to have excess play on the shaft.
The locator pin is a 7x5 solid step pin - in good shape, as well as the hole; the other pins are hollow - all fit nicely into the case and the bearings