Im about to start a full top end rebuild on my Sec...I have the use of a shop, tools etc and all parts required, I also have a factory service manual. what I really need to get started is a step by step( part by part) list of what to take off, in sequence. I think with the manual and correct tools I should be able to make this happen, jusy need to start and not sure where to begin ???
The job isn't too bad to do IMO. Patience is the key, simply because your nuts & bolts will be over 25-years old, & a lot of them undisturbed until now. You want a liquid spray like CRC handy for things like exhaust fasteners etc etc.
Personally, I always start from the bottom, & work back to the top, so that you're not above & below all day. A quick guide might be something like this, there's no real rights or wrongs, but use your common sense & the manual to mark things out that need to be re-aligned back into position on re-fit.
* Disconnect the battery.
* Spray the exhaust-pipe-fasteners with CRC or similar.
* Drain engine oil & radiator of all fluid.
* Remove exhaust pipes. ( I live in Oz, & our models are fitted with proper full twin systems ).
* Rotate the engine to TDC. ( Recheck once rocker-covers are off, or lift dizzy-cap away to confirm No.1 is at TDC ).
* Remove all belts.
* Remove timing chain tensioner. ( Often this is replaced with a new OEM item, along with the chain-guides ).
* Remove rocker covers.
* Check alignment of both camshaft positions, to confirm timing-chain serviceability.
* Remove fuel hoses.
* Remove & tag if necessary all electrical connexions.
* Remove intake manifold & associated rubber parts that may need to be disturbed. (Replace if needed).
* Remove your cylinder heads.
* Inspect & measure your cylinder-head bolts. Replace if stretched out-of-OEM specs.
* Inspect the threads in the block for the cylinder-head bolts. Clean-out & repair as required, including all surfaces.
* Reverse this sequence on re-assembly, & torque your bolts in sequence, & as advised by the manual.
Any further details would be found in the manual you have. Camshaft swapping can be completed after removal, or when cyl-head is still installed. Choice is yours. And DON'T MIX UP THE CAM FOLLOWERS or HYDRAULIC COMPENSATING ELEMENTS. They MUST be re-fitted into their same working positions, unless you're replacing with ALL NEW components.
Cheers,
Rastus
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