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Stupid mistake--any miracles out there?

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Dan Z50

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Discussion starter · #1 ·
So while trying to reinstall my cylinder, I was putting the cam chain roller wheel into place and managed to DROP THE METAL WASHER into the cam chain slot on the side of the cylinder and YES the damn thing went into the engine case.

I still can't believe that just happened. I can't get it with long tools or tweezers due to the gear inside the case. Anybody have any hail Mary ideas that might work short of splitting the enigine cases (my last resort).

See this is why I'm having Geezer build my other engine..what a dope I am!

(Land of the lost pictured below)
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Discussion starter · #8 ·
I have several telescoping magnets but they won't fit in the narrow slot next to that gear unfortunately. Only my thinnest screwdriver would fit, but then you can't see what your doing so now I have apparently pushed the washer enough that I can no longer see it. I still have the oil in the engine, that's why I hadn't tried shaking it or tilting it, even with it drained though I can't imagine it would come out since it now has oil on it. I too was thinking about taking off the stator stuff, just didn't want to if I didn't need to. Dang this sucks! Thanks for the advice!
 
Discussion starter · #11 ·
I decided to try and pull the flywheel and stator plate and hope I can find it back there, unfortunatly I can't get the flywheel off. I was able to get the nut off, and I have several flywheel and steering wheel pullers but none could get it off before the arms would let go.

So now I have to break down and buy a puller intended for this type of flywheel, does anyone know if I can find these at local auto parts places, and if so, is there some specific size or something I need to work on these? I know what they look like but no idea if they are sold in different sizes. I'd like to just grab one tomorrow instead of ordering or waiting until later in the week to go to my Honda dealer.

If anyone else has struggled with the bolt removal, check out how I did it below, just used a tow strap inserted into the flyweel opening (careful not to damage anything inside) and then wrapped and hooked the other end around the peg, worked like a charm.
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#12 ·
The flywheel puller is a one-off type deal, it is a 27mm x 1.0 pitch external thread puller with left-hand threads to attach it to the flywheel. The center bolt is standard right-hand threads to apply the pressure to the center of the crank end.

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#16 ·
If you're really skilled, you can take the clutch cover off and the oil pump. and then remove the shaft without splitting the cases. That will move the cam gear in the lower side which should give you enough room. Really though. I think you can shake it out if you took the clutch cover off.
 
#17 ·
Can u see it at all?

Id try like say a dental pick if you have one or a bent up piece of welding wire. If not id drain the oil n shake the bank, like a 5yr old that just heard the icecream truck coming down the road.
 
Discussion starter · #18 · (Edited)
I don't have air or impact tools in my current garage, otherwise yes that would have been the perfect way to go! That's why I posted my hillbilly method, in case anybody else doesn't have the right tools.

The washer is definately in the the lower case, I had the cylinder on the engine block and was trying to install the cam chain roller wheel so it had nowhere to go but inside the case, plus I could actually see it in there. I tried every thing I had in the garage but only managed to push it out of sight instead.

I'm going to get a correct flywheel puller, I'll eventually need one anyways for my mini's so we'll see if that works. If it doesn't I'll probably try shaking it out, I don't want to pull off the other side if I don't have to, cripes I'm getting closer to a total teardown at this point! I am "mechanical" but not a "mechanic" (obviously based on this stupid mistake!)

Thanks everyone for the tips and sympathy, what I thought was going to be a one day simple fix when I bought this mini has now dragged on for months and is getting pretty frustrating to say the least. Plus it's really killing my full resto on my other red/silver bike...no time and no space and winter is coming fast here.
 
Discussion starter · #20 ·
FINALLY!! Thought I'd give some closure to this embarrasing thread...I bought a flywheel puller at my local Honda dealer, got the flywheel off. But as Murphey's law would have it, the 2 phillips screws that hold the stator plate on were stripped out by somebody in the past and they aren't cracking loose.

I looked at an empty 1/2 crankcase, I'm not certain getting in there would have done it anyways. So since that wasn't coming off, I drained all the oil, and for about an hour shook the engine straight up and down with a tilt to the right to keep the washer in the corner it fell in, periodically fishing for it with a custom bent hanger and tweezers, eventually i got the dang thing out.
Image


Cripes what a freakin' nightmare that little mistake has been. So now that I am paranoid about REassembling it again, I have forgotten what order the parts below go together (apparently dimensia sets in about your late 40's I am finding). The cam roller wheel obviously goes inside the cylinder wall, then I have the washer, a rubber "O" ring and the bolt. Does the washer go inside the cylinder wall or on the outside, followed by the "O" ring and then bolt?
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I've got 2 sources for assembly but neither show the rubber "O" ring that was on it when I took it apart, or which side of the cylinder wall the washer goes on.

Thanks again everyone!
 
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