850 Reassembly Steps

Just poking around for the best reassembly guide.

I broke down my 850, took a gazillion pics, and kept good notes . . . but would love to have a "real" assembly guide.

Any good books and/or websites?

Start with the horn, everything else is optional how you do it.

Dave
69S

There should be enough build threads here to give you a good idea.

Ummmmm......

"By the book"

If it's a late mark III, you better install the airbox in the chassis first!

grandpaul . . . . what is this said book?

As I said, I documented the disassembly very well, just looking for a little extra reference on the rebuild. she is a '73.

I think he means a manual, any kind. It seems that no matter what methodology we use, there seem to be a "1 step forward,2 steps back" moment in any build. Dogt t isn't kidding about the horn nor Paul about the air box. Anything else is pretty much on your comfort level.
That being said, we are not speaking of the crankcase, gearbox, forks or the like, but the assembly of all the assemblies, right?
Just in case, Old Britts has an engine build check list and good gearbox break downs.

start somewhere and keep chugging. I can't tell you how many times I've had something done only to turn around and re-do it because I should've done something else first. It's a good learning experience.

As others have said there is an endless number of possibilities. But here are some things to think about. I have an 850 completely disassembled sitting in the shop waiting for me to get started.

My frame needs paint. I haven't figured out what to do about paint or powdercoat yet so instead I am going to get the engine and gearbox ready to go while I think about the frame. At some point I will have to make that decisions. Once there, I figure I will get the swingarm and cradle ready to go back in the frame. Get the gearbox in the cradle, endgine mounted, thus isolastics. It will then be time to get some wheels on there so hopefully I wll have something ready to go. Forks of course included. After that it is pretty much getting all the systems installed and working and bolting up all the bits that go along.

I dunno if this helps but it is the basic plan that I have.

Russ

I'm going to go from memory, but pretty fresh in my mind, and just having done the rolling chassis on my current build.

CHASSIS (not every detailed step documented, this is just general order stuff)

Oil swingarm bushings with 140wt (I leave mine soaking for a couple of hours), slip swingarm bushing dust caps onto bushings, draw them into swingarm with large bolt. Install spindle o-rings and insert swingarm on cradle, take care to position threaded end of spindle to timing (right) side, align bolt hole straight up as you push it in place. Grease rear isolastic lightly, smear inside of iso mount tube, press iso home. Install mount tube end caps & PTFEs. Thread on end lugs, observe orientation. Install rubber booties on isos if you intend to use them (some don't like using them). Set rear end in position and slide in clean iso mount bolt. Install shocks. install swingarm spindle end caps with o-rings and fill withe 140wt.

Lightly oil clean headstock tube, insert top bearing and drift home carefully. insert bearing spacer from bottom, drift in lower bearing completely. Insert clean top yoke through top dust cap, install bottom yoke, tab washer & retainer nut, nip up (do not tighten). Assemble fork legs by the book. Observe correct fork leg for each side, insert screwdriver blade in lower yoke and gently tap in to spread open; draw up fork through bottom yoke, bottom o-ring, headlight ear, top o-ring, then top yoke. Install meter cup, washer and top nut; snug up (do not tighten). Repeat for other side.

Assemble & install wheels. Install handlebars. You now have a rolling chassis.

ENGINE (Again, not detailed, just general order)

Install main bearings, check crank end float, shim as required. Install rods to crank, install built up crank & cam with appropriate thrust washers per model. Nip up cases. If appropriate, install rear crankcase breather assembly. Install cam drive & oil pump. nip everything up & install cover. Install ignition rotor & stator, inspection cover.

Assemble transmission and install in tranny cradle (don't forget the thick spacer washer between the top mount & tranny cradle). Install front isolastics in front mount, assemble front mount to crankcases, install bottom end in chassis.

Test fit inner primary cover, check backside shimming to standoff post, shim as required to avoid stress fractures to crankcase mounting area (front three bolts). When front bolts are snug, you should have shimmed the standoff to the point that the shim(s) are just snugged up by adjuster nut.

Install engine sprocket & clutch basket (observe circlip, spacer cup & spacer shims as required) with primary chain all at once. Assemble clutch, install alternator rotor & spacer, etc. Install alternator stator, nip everything up & install cover.

Install pistons & rings, then cylinders with cam followers (base gasket). Assemble head leaving rocker settings loose, then install head with pushrods. I use thin strips of cloth jammed in pushrod tunnels to hold the pushrods captive in the head while I lower it in place. Just before setting it down on the head gasket, I pull out the strips of cloth. Fiddle the pushrods into place while peering through the exhaust rockerbox inspection openings with a small flashlight. Nip everything up.

Install carbs, headers, top steady, electrical, gas tank, etc.

FIRE IT UP!