Double Trouble....Elwood!

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Meatball
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Double Trouble....Elwood!

Post by Meatball »

This is a Winter build project that's been ongoing in the Meatball garage. 49cc's is fun but it would be double the fun with 98cc's! A 50x50 stroker beginning with a bare bones AF16 block. First order of business is to clean the motor completely.
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Re: Double Trouble

Post by Meatball »

Remove/replace all trans bearings and oil seals. I had to cobble together some makeshift bearing pullers since a few of them cant be pulled with a typical puller.
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Re: Double Trouble

Post by Meatball »

The case was cut to fit the 50mm stroke crank. It also had the intake windows, boost port and a couple other key spots opened up. Crank fits nicely.
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Re: Double Trouble

Post by Meatball »

First pic is of the untouched boost port with a Corsa base gasket. Next pic shows it with the stroker bore's base gasket with port work.
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Re: Double Trouble

Post by Meatball »

This will have a ZX trans so more cutting is needed. Grind out a couple bumps around the clutch area and belt travel zone. It might be too much but its better than not enough and shred belts.
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Re: Double Trouble

Post by Meatball »

This will have either a Polini or Malossi for Ruckus variator so more grinding needs to happen. The Dremel gets another workout.
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Re: Double Trouble

Post by Meatball »

Now that grind work is done, case was cleaned of all shavings and prepped for assembly. Starting with trans bearing install. Freezing them overnight and heating up the case with a torch makes install a snap. They dont exactly fall in but just a few light taps to get them seated. Finding an OEM Honda 6202 bearing isnt easy. All others are readily available everywhere but that one. I gave up and went with a quality Taiwan replacement.
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Re: Double Trouble

Post by Meatball »

Crank bearings went in easy with the freeze/heat/tap method. Also squeezed in new motor mount bushings for good measure.
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Re: Double Trouble

Post by Meatball »

Test fitting the oil pump plug and sealing it from the inside with JB Weld. I did this before crank bearings went in. You can see a bit of the intake window opened up. I shouldve taken more pics but I was "in the zone" and forgot to stop and snap a few. This post is out of sequence. :sad:
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Re: Double Trouble

Post by Meatball »

Pulling the crank is too easy with the TUSK tool. Almost like cheating. To seal up the case I used Yamabond. You'd be surprised how many Honda shops use this stuff over Hondabond.
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Re: Double Trouble

Post by Meatball »

Now that the PG full-circle 50mm stroke crank is installed and the case is sealed up, I move onto the 50mm bore. I went with a PG for that as well. They make good quality products but some prep work should be done before install. Time to bust out the Dremel again!
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Re: Double Trouble

Post by Meatball »

Taking a tiny jeweler's file I carefully chamferred the ports to remove the sharp edges. Its not much but enough to knock down the razor-like edges to let the rings happily slide by.
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Re: Double Trouble

Post by Meatball »

The exhaust port had rather large casting flaws so it needed to be sanded down smooth. Then I polished it to a mirror finish to allow better flow of exhaust gasses and to reduce carbon build-up.
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Re: Double Trouble

Post by Meatball »

Chamferring the edges around the transfer area also help. Pic shows mid-process. The final outcome looked much cleaner.
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Last edited by Meatball on Tue Nov 07, 2017 1:16 pm, edited 1 time in total.
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Re: Double Trouble

Post by Meatball »

After all the grinding on the bore, it was fully cleaned of all shavings and oiled. Now I can check the ring end gap. Surprisingly, one ring was within spec but the other was too tight and needed a couple passes on a file.
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