My 83 Honda 110 Rebuild Thread With Pictures!

[Rennat_2006]

I have been wanting/needing to do this for awhile now but have had to many unexpected projects in the meantime. I have finally got most of the bugs figured out in my 91 ktm 540 so the Honda has now taken its spot in the garage on the butchers block

Tore the top end off of it today and started looking everything over and doing some measuring.

This little thing had gotten to the point that it looked like i was running premix through it and had gotten harder and harder to start, It finally gave up the urge and wouldnt fire at all anymore. This was after rebuilding the carb and pull starter...Pull starter is broken again because of trying so hard to get it running.

Heres some of the many pictures ive got so far...



This is the only real problem i have with the cylinder, I figure the cylinder will have to be bored out to fix this put how much i dont know and am somewhat scared about.

Here is another problem area, What do you guys think am i going to have to replace the head?

[Rennat_2006]

Cylinder doesnt seem to have any real bad scoring. I do not have a bore gauge to see if it is out of round or how worn it is though, I will do some asking around at work tommorow and see if anyone has one.




Piston also doesnt have any major scoring either, It does have some chunks missing like the head does pictured above.

Here is some measurements i have gotten so far...
These have just been taken with a cheap harbor freight Digital Caliper http://www.harborfreight.com/cpi/cta...emnumber=93293
Camshaft
-Right side=17.6mm
-Left Side=25.6mm
Specs
-Right=17.927-17.938mm
-Left=25.917-25.930
Service Limits
-Right=17.90mm
-Left=25.90mm
Camshaft Lobe Height
-Intake/Exhaust=24.3mm and 24.4mm
Specs
-24.90mm
-24.98mm
Service Limit
-24.6mm

Cylinder Warpage
-0.00mm
Service Limit
-0.10mm

Piston/Piston Ring
Top Ring
-0.23mm
Second Ring
-0.05mm
Specs
Top Ring
-0.015-0.050mm
Second Ring
-0.010-0.0045mm
Service Limits
Top
-0.12mm
Second
-0.12mm

Ring End Gap In Cylinder
Top
-Over 0.80mm
Second
-I broke the 2nd Ring trying to take it off so we will just say it was outta specs
Specs
Top
-0.15mm-0.35mm
Second
-0.15mm-0.35mm

Piston Skirt Diameter
-51.8mm
Specs
-51.970-51.990mm
Service Limit
-51.80mm
So if my measurements are correct im within specs here but it is getting replaced anyways

Piston Pin Hole
-14.8mm
Specs
15.002-15.008mm
Service Limit
-15.04mm

Piston Pin O.D.
14.7mm
Specs
14.994-15.000mm
Service Limit
14.96mm

Piston/Piston Pin Clearance
-0.01mm
Service Limit
0.02mm
So even if my measurements arent dead on it shows im within specs with the clearance between the two of them

Going by the manauls i uploaded for everyone else in another thread made this a real easy job so far, It has all been Step by Step.

So i still need to tear the head apart and check the valve guides, Valves, Springs, Etc up there and make a complete list of everything that is going to be necessary to replace. I also need to find someone to do the machine work on it and i dont know if i should just send the complete top end down there and let them go through it all and take all of the measurements or just do the measurements myself and hope for the best.

So what do you think, Anything i have missed so far or any tips?

Im thinking about putting a little better performing cam in it, Anybody ever done any porting/polishing on the Intake, Intake port, and the Exhaust Port?

[Rennat_2006]

I have decided to go this route for the rebuild,
Rebuild Kit
Sounds pretty hard to beat for $129 bucks when i have found pistons for $70.

Probably going to put a bigger cam in it also.

[70ATC90]

Yeah thats probably a good idea. If you have any questions PM me.

[Darius1502]

Sounds good Rennat! I remember those 110's when I was kid. I played on an '82 quite a bit.

(yes this is DariusKTM) hehe!!

Man those '83's had totally new styling. OH they were so pretty. Oh and the blue ones...wow! In the showroom they would just shine!

[Rennat_2006]

Yeah they are a neat little machine.

Mine isnt pretty, My KTM isnt pretty either but that doesnt really bother me, I would rather have them look "Decent" and enjoy them than have them show worthy.(See Darius's KTM) The Honda needs the plastics replaced, About the only thing left is the seat pan. lol

Where have you guys boughten cams for these things at before? I have found some on Webcamshafts.com i believe it was but it doesnt list any prices.