Honda Spree and Elite 50 Forums

14 months of procrastination ended Thursday.
I attempted the BBK install.
All was going well. Got the old piston & jug off, greased up the new one, got it on. Discover my torque wrench only goes as low as 20lbs, but forum consensus says 14lbs. I decide to go for it and wing it. Didn't lose any circlips into the crank. The jug seems not on straight, I figure the bolts will straighten it out. None of the bolts are grabbing. Pull the bolts, pull the head, then put my rag on jug & start with the mallet. Start again with the cross pattern of the head bolts, 3 grab, 4th won't even go in the hole. Mallet it down in frustration. Realize this isn't going right. Decide to try and repair the tabs on my body panels to cool off (spent 4 hours trying to do this). As I started to open the tube to cement the screen to the panels, I sliced open my hand, preventing me from further damage to the bike.
I may just give it up and take it to Ace Motorcycle Mechanics later next month, and try and get my NU50 running.
Advice?

Get longer head bolts lol

Pics might help?

The cyl not sitting down straight and that the bolts wont reach should have told you to stop and find out the issue before using a mallet on it.
Hope you didnt ruin anything

I'd figured one bolt grabbing would pull the jug inline.

Pictures of what would help?

How did you slice you hand with a mallet?

Eft37 wrote:
Pictures of what would help?

Pictures of puppies.

That helps my mood!

Eft37 wrote:That helps my mood!

Looking at pictures of puppies lowers frustration levels.

take a picture of the "jug that doesn't seem to sit straight".

http://www.dropbox.com/s/rf2k2vvriywn3h ... 192136.jpg
and
https://www.dropbox.com/s/ffmxwlcwzj17f ... 192143.jpg
and
https://www.dropbox.com/s/ffmxwlcwzj17f ... 192143.jpg
also
https://www.dropbox.com/s/oeyxkr2eqw0l7 ... 192157.jpg
but
https://www.dropbox.com/s/aw8kmbipjt8qs ... 192202.jpg
and then
https://www.dropbox.com/s/v5u2rgvjl8xjz ... 192207.jpg

Sorry I cant make out anything wrong in your pics... does the piston move freely in the bore?

It does.

I'm going to bring it in to the shop next month, will proceed to work on/break my Urban Express in the meantime.

I got new bolts, hoping I'd just ruined the old ones. I had my neighbor help, we discovered the 2 exhaust-side holes weren't grabbing, he suggested I get a same size tap and see if the threads in the case were just dirty. I ran the tap in, and it went fine, but I used compressed air and a lot of metal flakes came flying out. I tried to then use the new bolts, but they didn't grab, so the holes are shot. Need to get them tapped and threaded. Advise please.

Sorry your having a difficult time. First time doing anything is always rough. Make sure you didnt get any shavings in the case. To the bolts go in when the jug is completely off? They make head stud kits but ive never once had problems using the stock bolts. Defiantely never ever use a mallet while installing your bore. Ever

You can NOT use the stock length bolts for a 50 mm jug, you should use studs or longer bolts. If you side by side the jugs you will see the problem.