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Jan 27, 2009--
[Click pictures for a better view]
Waiting for new crank and rod bearings. Cleaning up crankcase and other parts.
Jan 30, 2009--
The factory manual says that the cam bushings rarely need replacing unless there is very high mileage. On mine, with the cams installed dry, there was a nice slip fit on the right (big) end, but the left end was loose. I could move the cam back and forth and hear it click.
The old bushes don't give up easily--I had to collapse them with a small punch, trying not to damage the bore.
The bushes are split (although it was impossible to tell where the seam was on the old ones). I made a simple drift to get them in.
Pressed them in:
The new bushes were actually a little too tight. I don't have a good way to ream then, so I used a brake cylinder hone to get the fit right.
Crank is ready to go together. It's been de-sludged, and all the oil galleries cleaned and flushed. It has been ground 0.010 under, and gets a new sludge tube (ruined the old one extracting it), and a new hex plug (likewise). New big-end bearings, too, obviously. Also new big-end cap nuts. Some say the big-end bolts should be replaced, too, but I've never done that on other engines. Factory manual recommends new nuts.
I thought I'd have main bearings today so I could assemble the case. The ball bearing on the right side was easy, but the roller bearing on the left had to be ordered. First quote I got for the roller bearing was almost $200, but I eventually found it for less than half that.
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