2008 May 26: Acid cleaning and engine assembly and tire mounting (4.00 hours)

Updated: 2008 May 26

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Cleaned all the cases with Eagle One Etching cleaner. It did a great job on the engine case. The remaining cases must be comprised of a different alloy mix. They cleaned up well, but just not as well as the engine case (and all cases were prepped identically).
Cleaned the sidewalls of both tires with Bleche White. It worked very well at removing the brown gunk that had settled on the sidewalls.
Installed the camshaft and cam followers.
Installed new plug into the sludge trap of the crankshaft, secured with high strength thread locking compound and peened into place.
Fit the front main bearing. The pivot plate for the timing chain tensioner was fitted as well.
Removed old outer race from the oil pump bearing.
Installed inner and outer races of the new bearing for the oil pump.
J-B WELD the cam plug.
Fit the crankshaft in the front main bearing.
Fit the rear main seal in the rear main bearing.
Fit the rear main bearing. A new gasket was fitted, coated with Permatex Super 300 Form-A-Gasket Sealant. The threads on the bottom two bolts were sealed with ThreeBond 1184 semidrying liquid gasket.
Fit the oil return line from the breather, with new crush washers. A Schnorr washer was used at the securing bracket.
Assembly lube was used on all applicable surfaces.
Converted the rim to tubeless. The powder coating took care of the internal sealing needs; a valve stem took care of the rest.
Mounted tire on rear wheel. Tire went on easily, but I struggled to get the bead to pop into place. Plenty of tire mounting lube, more than a bit of struggling with a ratchet strap, and I finally got it done. Took 1 hour just for this.

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