I finally found a pilot Engine (thanks dan) and it arrived safely.
It supposed to work and run fine...and I know if its not broke don't fix it...
but...I want to take it a apart and document it fix what needs fixing then take the one out of my pilot and do the same. so here is my question. Is there anything that I can really mess up when taking it apart? ( I know you have to put it back together correctly)

Thanks and pics will be posted on my site
Monkey wrench

Box it back up and send the whole thing to PCP racing haha

Sure there's lots you can screw up.

1. loose parts
2. crack your flywheel on removal
3. ruin your clutch on removal
4. pry the cylinder off with a screwdriver
5. same on the head
6. same on the cases
7. drop the crank
8. list goes on.....

If you have the right tools and keep track of parts and take your time, follow the manaul, you should be OK. But yes, as with everything, of course it can be screwed up.

Assembly is of course worse!

I took some photos when I did my rebuild and posted them on the POG. I'll do the same again when I tear down my spare.

People do themselves a great injustice when they DON'T spend some of their web time going thru Hoser's board and his Tech articles.

I guess it may seem overwhelming to many but Hoser has created such a wealth of info its invaluable. Coupled together with a service manual, there is no service or repair that any guy with patience and a set of tools can do better than your local honda shop.

The main difference is that the typical Honda service rep is just some guy who is thinking about what time he is geting off work, or why his old lady didn't ((Bad Word)) him last week, or why the boss is such a dickhead. The honda guy don't care anywhere near as much as you do about your toy.

With that being said here are some links, but no where near all of them. spend time exploring.

The Main Pages
http://pilotodyssey.com/pilottech.htm
http://pilotodyssey.com/tech.htm


Some individual articles that should apply to your current project. Many are multiple pages, be sure to "next" or "more pictures" at bottom of page to view the entire article.


http://pilotodyssey.com/rebuild1.htm

http://pilotodyssey.com/basket1.htm

http://pilotodyssey.com/Pilotinspection2001.htm

http://pilotodyssey.com/inspect2.htm



This wasn't directed at you personally MW, you just provided a vehicle to hopefully tell a bunch of others the same thing they wouldn't or haven't asked.

Yeah my site is getting a little overwhelming but never the less the stuff is all there and easy
to find, on the main page there is a link "Technical Information Center For the Pilot" there
is also a link Technical Information Center General on these pages there is lots of info.....

I have this on the top of my Technical page

"Engine rebuilding is nearly impossible without the right tools. Some guys try to use the
“caveman” method—big hammers and chisels. As a result, they usually do some stupid
thing that ruins expensive Engine components." A good start is to buy and read a factory
service manual! it is a invaluable tool and includes pictures so you can see what is inside
before you pry it apart."

Its there for a reason, its there to make you think, I don t and cant give you all the
details needed that may be required to work on your Pilot so alot of thinking will be
required on your part, are you a com penitent mechanic, you think you can pull this
off and make it work? out one of them guys that are more interested in what your
Pilot looks like so your main interest will be to remove the cylinder as quickly as
possible so you can sand blast it and make it look cool and in the process you will
lose all the valuable info and tel tale marks your cylinder has to tell you when it is
first removed?

If someone told you to grab the end of your axle and use it for a slide hammer to
remove you inboard joint from the output shaft would you be dumb enough to do
it or would you be smart enough to think or maybe ask someone else? , I bring
this up because I know someone who was given that stupid advice and the end
was a junk axle and CV not to mention 3 days of lost riding and free access to one
of the best Pilot mechanics in the world. It "looked pretty setting there all weekend"

Are you one of them guys that feels the need to use power tools for everything he does?
Impact wrenches have no place on a delicate Engine like a Pilot Engine, the ONLY
exception would be using one to remove your clutch , another example
would be using a power abrasive wheel to remove gaskets or gasket residue on
a aluminum surface, like my tooth paste tube label says "do not swallow" I bring
this up because I have seen clue less morons on more than one occasion attack
their parts with "gasket scrapers" and power tools when all they needed was TIME
and a single edge razor blade, I could go on or days about the little things that make
a difference between a good mechanic and a GREAT mechanic, there are literally
hundreds of observations that need to be made before, during and after a Engine
rebuild to make it successful and long lived..

With all that being said I would be happy to disassemble your Engine inspect and
rebuild for a reasonable price, so reasonable I would allow you to set what you
think is a fair price for my services.

I totally agree with Hare.....read alot of stuff on Hoser's site. Read the manual as well.......long before you put a tool on it. You will need to get a crank puller or you can make one. The link that helped me the most was: http://www.dirtcheapracing.com/tech/bottom/. Its really important that you have a clean work area too. I just did my first one before xmas, I had never done a split case 2 stroke motor (( Internal Combustion Engine ? )) previous to that and it went well. With all the discussions about main bearings in the chat, I would replace them on principle, even if you think they don't need it. Most importantly just take your time and stop to ask questions when you are unsure.

Well Like always...great advice.
I especially liked "would you be dumb enough to do
it or would you be smart enough to think or maybe ask someone else"

wow that was brilliant.
Well Im no rock star mechanic, hell Im not even a mechanic.
I love the pilot and want to learn more about them. If I take the Engine apart I can take photos, label them and get my website back up selling NEW parts for the pilot.
anyone remember hondapilotparts.com?

I would really like to travel to the windy city and get the expert advice from hoser...or even travel south and have Nick show me a thing or two. There is Pilot talent north east south and west. I just want to learn and get my hands busy with an Engine that I can handle (barely) Its friggin heavy if your in a wheelchair.

Im sure I'll screw something up...but it would be documented...and I could always run up to Hillside Honda!

Monkeywrench