Specialty tools for engine builds

[dogger315]

Here are pictures and descriptions of some of the specialized tools used
to assemble the Honda CR250 engine in the series of build article. These
tools are the same used for any brand of engine.

Like anything else, you get what you pay for. I try to look at tools as an
investment. One brand I can recommend that IS inexpensive is Tusk.
These tools are available from Rocky Mountain MC/ATV.


Case splitter. This one is made by Motion Pro and can be used to split the
cases of most if not all motorcycles. The long screws pictured are threaded
through adaptors in the movable tool arms into exisisting screw holes in a
triangulated pattern to distribute the load. The jack screw is placed against
the crankshaft pin and tightened pulling the "captured" case half apart.
This tool can also be used to remove and install the crankshaft.


Crankshaft Installer. This one is made by Tusk. The jack screw comes with
various adaptors that thread into most types of crankshaft pins. The
jackscrew housing is placed over the crankpin and seats against the case.
The jackscrew is tightened drawing the crankshaft into the main bearing in a
slow controlled motion.


Blind bearing remover. This kit is used to remove the numerous blind (bearings
that cannot be reached from both sides) bearings found on most engines.
The adaptor is sized for the bearing and is inserted and tightened to expand
and seat it. The slide puller is threaded into the adaptor and the weighted
ring is slid back with force until the bearing is removed.


Cylinder bore gauge. This tool is used to measure the diameter and
concentricity of the cylinder bore. This is an important step to determine
if the cylinder is in limits during a build or just a "top end" job.


Here are some miscelaneous tools that I use. Clockwise from top, Universal
holder. This one is made by Honda and can be used to remove/install the
clutch outer, stator and countershaft sprocket.

Next is a torque wrench extender. Two of the cylinder bolts on the engine
I am building are not accesible by socket. this wrench is placed over the
cylinder nut and a torque wrench is snapped into the middle and a pre
determined torque value can be applied to tighten the cylinder nut to spec.

Next is a clutch tool. This one is made by Motion Pro. It is used to hold
the clutch outer while tightening the mainshaft bolt. It also can be used
to hold the countershaft sprocket and Stator.

And last is a gear jammer. This one is by Motion Pro and is used exactly
how the name implies. You place it between two adjacent gears to prevent
movement when loosening or tightening bolts. A penny works in most cases
but I like this tool because 1) it's magnetized (hard for it to fall into the
abyss) and 2) unlike a penny, this one works on the plastic water pump gear.



Two stroke leak down tester. This one is made by Motion Pro. As the name
implies it checks for air leaks in your motor. The importance of this test can
not be overstated. A two stroke is completely dependent on vacuum to run
correctly. Air leaks at the crank seals, intake, center case, etc. can cause
all sorts of problems. To test, block all the ports to the outside with the
supplied covers, insert the adaptor into the intake boot and clamp, then
pump the motor up to six psi and time. If it holds pressure for 2 minutes,
you are OK, longer is better.

Hope this helps. If you have any questions, please post them. I'll do my
best to answer.

dogger

[AJ_YFZ]

Nice write-up....Sure this will help alot of people

[Woody_393]

Awesome! I can honestly say I did not recognize more of those tools. In fact the leak down tester is the only one I recognized on first view.

Thanks Dogger, I appreciate this.

[Big Maico 393]

I recognize all of those tools & know how to use them too!

But owning a Old Maico, I just don't own any of them!

No need to, you just need a 5lb hammer & a few chisel's

Just kidding, I do have a clutch tool,dial indicator, seal puller & a torque wrench.

I would love to be able to have all those tools to put in my tool box, someday soon!

[OLDMXRACER 393]

I wish I had some of those tools, but I wouldn't know what to do with them!
Don't need any chisel's for 'hunerd Hodaka's Howard. Just a cresent wrench and a 2lb hammer.

[dogger315]

Alright you two. If this keeps up, I'll have to start a shelter for
abused bikes.

dogger