CD90Z - head & cylinder

Time to sort out the smoking. On dismantling the head I found the valve gear and cams in good condition. I then moved onto getting the cylinder off. However this turned out to be a bit of a chore as the bolt for the chain guide roller was seized into the head and had very rounded corners. After attempts with various sockets and spanners I decided to cut a slot and try an impact driver - one broken driver bit later and the bolt was still in place, almost laughing at me. Then I discovered a tool called an Irwin Bolt Grip Remover, I read the online reviews and thought it probably wouldn't work... anyway I went and spent £22 and invested in the set of five sockets. Approximately one minute after walking into my garage I had removed the offending bolt. Amazing, it actually worked so well I didn't believe it had undone the bolt at first - certainly a good bit of kit for the toolbox.

So, cylinder off and I could see the piston. A touch of very light scoring on the piston and cylinder so I think I'll try and get away with it. Lots of yucky gasket goo and a fair bit of cleaning up to do, but the condition of the components was pretty good. One thing I did find, or rather didn't find was the oil seal on the exhaust valve guide... no sign of it so maybe that could be a major cause of the smoke - fingers crossed.

CD90Z - under the covers

I took the covers off today, I thought I'd better see what horrors lay hidden underneath. But it was a pleasant surprise as you can see, especially considering the amount of water that was in engine 10 years ago when I got the bike off my brother. Now cleaned out and looking good, I'm intending putting the covers back on using stainless allen bolts and new gaskets I bought off ebay.  A bargain I thought  - two complete engine sets (one missing a head gasket) for around £9 plus postage. As a matter of interest I bought a couple of cables off John Oldfield, a non-franchised Honda dealer, great price and fast delivery. I've now ordered brake shoes and some other bits - a useful source, have a look (the link is top on my links list at the moment). Please mention the blog if you use him, he might give me a discount!  Here is the link just to make it easier.  

Ok, just to prove that the CD90Z will actually start and run here is a first video. Excuse the rattling noise - it is not the sound of the engine it is in fact the rear light and number plate holder which I've yet to secure properly. Considering that I haven't tuned the carb, or ignition and have only put in a new plug and fresh petrol it runs quite smoothly. The exhaust silencer is chopped off an old exhaust, (no idea what from), and connected to what was left of the original exhaust system with a jubilee clip. The carb is fed from an old lawnmower petrol tank. The spark is powered from a 6v transformer (no battery as yet) and the ignition switch is two wires twisted together. All a bit Heath Robinson but the good news is that it starts pretty easily. I put in some fresh 20/50 oil I had lying around but will be taking off the cases and inspecting prior to putting in the correct oil and refitting cases with stainless bolts. Still loads of work to do and lots of bits to acquire but the rebuild is at least progressing well.  I'm hoping to pick up a few bits at the BMF rally in Peterborough.