044 hybrid build CFB style

[Canadian farm boy]

After having the 3/4 wrap handle powder coated I had to install some new rubber on it.
I made up a fitting so I could attach shop air to it and lubed up the handle bar with some dish soap. Set the shop air to approximately 40psi and pushed/pulled the new rubber on.
After getting the rubber on I wrapped a couple pieces of tape around the locations I wanted to cut the rubber at. The tape provides a straight edge for cutting the rubber.
Oh and the dish soap was green apple scented. Lol

 

[p61 western]

I need to find a beat but buildable saw for this deal. Thank you for the details Mike. It will definitely help me I know that.

 

[Canadian farm boy]

Since the cases were totally stripped down I decided I would match them up a little better. I simply screwed the cases together with 2 screws and marked these spots. I couple minutes with a burr and the cases matched up nearly perfect.
I will note that this is something that isn't always needed. The 046 piston does come close to touching when at BDC but I've never seen one actually make contact.

 

[Canadian farm boy]

When installing the clutch side crank bearing you have to install the oil pump first. The oil pump acts a stopper and sets the bearing depth.
Before heating the case half I like to apply a thin coat of permatex 518 to gasket surface. Easier to do it before rather then after the case is hot. I like to heat the case with a propane torch. I hold onto the top corner of the case while I'm heating it. When it's about to hot to hold onto I know it's ready to have the bearing dropped in.

 

[Canadian farm boy]

Installing the FW side bearing is basically a repeat of the same procedure. In this picture I have a thin coat of permatex 518 on the gasket surface and the gasket in place. If you work fast enough and you have the cases hot enough the bearings will become slightly heat soaked. I can usually drop the bearings in and then quickly put the crank shaft in place. I apply a bit of down pressure with just my hand and once the bearing expands enough from the heat of the case the crank will slide right into place.
It sounds tricky and you have to work fast. Once you've done a few it's not to bad.
Here's the assembled cases

 

[Canadian farm boy]

The case gasket extends a bit past the top of case. I simply trim the extra off with a sharp razor blade.

 

[Canadian farm boy]

After assembling the cases and everything cools down it's sometimes nesassary to relieve a bit of tension from the bearings to allow the crank to spin nice and free. Easiest way to relieve the tension is to place a piece of brass or aluminum or even a piece of wood against the end of the crank shaft and give it firm but gentle whack with a hammer.

Here's the assembled cases all ready to go with the bearing tension relieved

 

[Canadian farm boy]

FW side crank seal going in. I coat the outside of the seal with more 518 and the rubber lip gets a liberal coating of synthetic grease. The synthetic grease I use is actually dielectric grease and doesn't react or harm the rubber.

 

[Stump Shot]

After assembling the cases and everything cools down it's sometimes nesassary to relieve a bit of tension from the bearings to allow the crank to spin nice and free. Easiest way to relieve the tension is to place a piece of brass or aluminum or even a piece of wood against the end of the crank shaft and give it firm but gentle whack with a hammer.

Here's the assembled cases all ready to go with the bearing tension relieved

That's the way they should be, good job!

 

[Canadian farm boy]

Clutch side crank seal. Again more 518 on the outside of the seal and more grease on the rubber lip. Little trick I like to do is to put seal the on the bearing spacer and install them as an assembly. The clutch side seal depth is very important. The seal has to sit flush with edge of bearing race. To deep and it will take a beating from the bearing cage. Not deep enough and it won't ride on the bearing spacer properly.

 

[Canadian farm boy]

Missed a couple pictures from the fuel tank assembly. Oops. Lol.
Pretty self explanatory here

 

[Canadian farm boy]

Oil pump pick up body and hose installed in the cases and then the oil pump can be installed

 

[Canadian farm boy]

Chain brake assembly going together

 

[Canadian farm boy]

Big azz spring installed and the brake band installed. The brake band gets anchored with 1 screw in the bottom of crank case

 

[Canadian farm boy]

Chain brake covers can go on. The small piece needs to go on first.

 

[Canadian farm boy]

Chain tensioner.

 

[MotherGoose]

Everything is so clean

 

[Canadian farm boy]

New AV rubbers. Lube em up and just push em home

 

[Adirondackstihl]

You’re on a roll tonite Mr.Eagle!

 

[Canadian farm boy]

New upper AV mount.
This grommet is important. The coil wires will get fed through it