Monday, August 19, 2013

82 Virago Valve Job and Engine Assembly

We have everything powder coated and polished and its time to disassemble the heads and face the valve seats.  Deuce picked up 2 different valve spring compressors and neither one would clear the head and allow us to get the retainer clips out so he had to improvise. 
Deuce took and old socket and cut one side off with the plasma.

Now we can get the compression we need and still have access to the retainer clips.


We needed to pull the rocker arm sleeves to move the rocker arms out of the way of the springs. 

A 10 mm bolt and bunch of washers worked nicely.  Pulled the sleeves out just past the rocker arms so they could be pushed out of the way.
Here is the sleeve with my "puller" still attached.

Pulling the 2 from the other head while Deuce is running around taking pictures, I never noticed the tiny stool sneaking up on me!
A C-clamp and our custom tool made removing the springs simple.


It isn't pretty but it worked great.
Lapped the valves after a thorough cleaning in the parts washer.
Reinstalled the valves the same way they came out.  Assembly lube on everything and a little lube on the retainers to hold them in place.
Deuce lubing up the cylinders so he can hone them and get the crosshatching.


 
Running the hone making sure not to stop while the hone is inside the cylinder.
Cleaning everything up getting ready for assembly.
New gasket kit with everything except the gaskets to split the case.  We inspected the inside of the case and it looks great so we didn't split it.


We couldn't find a ring compressor that broke apart so again we had to improvise and use a hose clamp.  It worked great.


Here is the compressor that wouldn't work for us.
 
One Jug back on with the timing chain and guides fed through.

2 Jugs

The Head crush gaskets were a little too tight to get into the groove so we stretched them just a little and they fell into place.

And here it is, the heads have been redone, the cylinders honed and cleaned, new gaskets throughout, jugs powder coated and all the aluminum cleaned and polished.  Looks pretty good for an 31 year old Yamaha motor.












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