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Tech Section / Re: Splitting engine without removing top-end
« Last post by patrino on Today at 10:23:19 am »
Good luck!

No specific advice, though I've known plenty of folks who've done this on other makes/models.

I suspect you'll want to remove the clutch at least, and pulling the alternator rotor probably isn't a bad idea.  I've done plenty of engine rebuilds, but always pull the top end.  Often there are bearing retainer circlips or plates that span the crankcase mating surfaces, and there may be some hiding behind clutch may be hiding some. 

Please keep us posted on how it goes!
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The Thumper Years: Modified To Full Customs / Re: Dutch FT project
« Last post by hellblom on April 08, 2020, 01:32:10 pm »
Yes, please do!
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Tech Section / Splitting engine without removing top-end
« Last post by kansloos161 on April 07, 2020, 02:48:17 am »
I am looking into the possibility to add a kick start to my FT.
In order to fit the kick start axle I have t split the cases and mount the kick start in the bottom case.
My top-end is completely fine so if possible I would rather keep that intact.

I've read that it is possible to split the cases without removing the cilinder, but the question is, what do I need to remove and how do I proceed in splitting and reassembling the cases.

According to the manual you have to remove the full top-end, the balancer chain, the clutch, oilpump and the alternator. But they remove the upper case. I intend to remove the lower case and keep the gearbox in the upper case.

What I've read online this should be possible without removing the top end (but no info on clutch, alternator, oilpump etc), apparently the only difficulty is realigning the shiftforks when reassembling.
Does anyone have any experience with this?
No need to remove anything but the side covers and the case pinch bolts?
How hard is it to re-align the shiftforks and is there a best way of working?
Any risk of misaligning something (balancer or cam chain) when reassembling?

Edit: found this video: https://www.youtube.com/watch?v=Hz5uocZdlpI seems that this guy has split the cases of a Xl500R without taking the top-end of and without taking the generator of. Clutch is of though.

Regards,
Paul
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The Thumper Years: Modified To Full Customs / Re: Dutch FT project
« Last post by J6G1Z on April 06, 2020, 10:03:08 am »
Please do. It would be nice to have a functioning kicker as a back-up. Good luck.
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The Thumper Years: Modified To Full Customs / Re: Dutch FT project
« Last post by kansloos161 on April 06, 2020, 05:12:00 am »
@J6G1Z.
I recall that too.
I've seen some bodged up fixes but nothing very fancy.

I have been offered some of the parts needed for the kickstart conversion for a very reasonable price so I am really thinking about doing that.
The specific FT500 starter gears that broke are just completely unobtainable or people ask top money.
If I am going to do the conversion I will do a detailed write-up in the tech section including the search for a decent looking and fitting kickstarter.
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The Thumper Years: Modified To Full Customs / Re: Dutch FT project
« Last post by J6G1Z on April 05, 2020, 11:35:47 am »
I recall a few posts on converting to a kick-starter. They then had a problem with the kicker & foot-peg interference. I don't recall ever reading about or seeing a solution.
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The Thumper Years: Modified To Full Customs / Re: Dutch FT project
« Last post by kansloos161 on April 03, 2020, 03:05:46 pm »
That's strange, I think you might be right and as far as I can remember now I also ordered that XR one.
I do remember it not being in the FT parts list and looking exactly like this XR one.
Because I couldn't really remember anymore I looked up the invoice.
On my invoice it says 12316-473-000 as part number though...
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The Thumper Years: Modified To Full Customs / Re: Dutch FT project
« Last post by scottly on April 03, 2020, 01:12:43 pm »
Nice going on the electrics! It's fun to follow your progress, I am in the midst of tampering with my bike as well due to the lockdown. I am really interested in knowing more about the "plug" for the hole in the cylinder that the tacho leaves when you remove it. Do you have a good link for somewhere I can buy it? I live in Sweden, so a European site is preferable.

I checked my old orders and I believe it's this part:
https://www.cmsnl.com/products/cap-head-cover_12316473000/#.XoWG5ogzbIU
only 3 euros and they deliver everywhere in the world.
It's number 2 on this diagram so it is actually meant to plug this hole:
https://www.cmsnl.com/honda-ft500-1982-c_model50099/partslist/0034.html#.XoWH34gzbIU
Might be worthwile to order some more parts with them because of the postal fees.

By the way if you are going to replace your exhaust studs. Order these, these are the correct length FT500 ones (XL500 ones are shorter)
https://www.cmsnl.com/search/?section=all&q=92900-060350B&tab=schematic

If any of you has the starter side of the FT500 open and could check for play on the starter gears that would be awesome!
I don't think that plug is for the tach? It looks like the plug for the compression release, which the FT doesn't have. I used the plug from an '82 XR500:
https://www.cmsnl.com/honda-xr500r-1982-c_model50091/plug-camshaft_12312428000/#.XodqP3JlC5g
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The Thumper Years: Modified To Full Customs / Re: Dutch FT project
« Last post by kansloos161 on April 03, 2020, 08:57:45 am »
@hellblom.
Thinking about doing the kickstart conversion. The gears that broke are FT500 specific and completely unobtainable.. Might be nice to install a kickstarter and be done with relying on these parts. Making a list of parts that I would need to do the conversion now as I cannot find a decent write up of a total conversion. Oh and good luck with the tank!

@Murdo.
I will test the stator wiring, although I fear the worst and also wouldn't want to ride around with a stator that is about to fail. So also looking at replacing it but again the stator is also a FT500 specific piece (apart from an obscure cb250 variant).

Really hope this doesn't sideline my project.
I at least want to make sure I refurbish this stator or get a new one and could even do with bumpstarting but would be best to get either a kickstart or the gears for the electrical starter. I've put so many effort in this bike it would just be such a shame to stop it now.
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The Thumper Years: Modified To Full Customs / Re: Dutch FT project
« Last post by murdo on April 03, 2020, 04:00:50 am »
Bad news about the starter gears. So long as the stator windings (wires) are not broken then just smooth up the metal bits and it should still work ok.
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