Okay, so today I tackled the big one: the engine on my old 1985 Honda Shadow VT1100. Thing was knocking like crazy last season, figured the bottom end needed love. Time to tear into it!
First up, got the engine out of the frame. Man, that’s always a wrestling match. Unhooked all the cables, wires, and fuel lines. Took the exhaust pipes off too, they were crusty and fought me. Got the mounting bolts finally loose after soaking them in penetrant overnight, and hoisted it out onto my workbench with my engine stand. Solid start.
With it on the bench, the real fun began. Took the whole engine apart, piece by piece. Started with the top end – valve covers came off, revealing those old rockers. Then yanked the cylinder heads off. Pistons looked worn, rings were definitely shot. Took the timing chain off carefully, marked the gears so I wouldn’t mess it up later. Then cracked open the crankcase – that’s where the bad noise was coming from, right? Pulled out the crankshaft, connecting rods with pistons still attached, and that big old main bearing set. Everything felt rough, not smooth like it should.
Next step, cleaning and checking everything. Spent ages scrubbing parts in solvent. Got everything laid out on a clean rag. Measured the crankshaft journals with a micrometer – yep, worn beyond spec. Those main bearings were totally chewed up. Checked the cylinder walls too; needed a light hone for sure. Found a couple of valve springs feeling weak. Made my list: new main bearings, rod bearings, piston rings, a full gasket set, valve seals, and figured I’d toss in fresh clutch plates while it was all out.
Once all the shiny new parts arrived, it was time for putting Humpty Dumpty back together. Started deep inside the crankcase halves. Pressed in the new crankshaft bearings nice and careful. Laid the crankshaft back into the bottom case. Slapped new rod bearings onto the cranks, attached the pistons (with new rings!) to the rods, and painstakingly lowered them into the cylinders. Torqued the rod caps down just right. Mated the crankcase halves together, sealed it up good with that fresh base gasket. Bolted the cylinder heads back on, installed the valves with the new seals, set the rocker arms. Put the timing chain back on, lining up the marks I made exactly. Slapped the valve covers on. Dropped in the new clutch plates before sealing up that cover too.
Finally, got that cleaned-up engine back into the bike frame. Heavy lifting again! Hooked all the wires, cables, and throttle linkages back up. Reconnected the fuel lines. Fresh oil and filter in, coolant filled up.
Time to fire it up. Honestly? Held my breath turning the key. Hit the starter… cranked for a second… and then it ROARED to life. Smooth! No clatters, no knocks. That new bottom end purred like a happy kitten. Let it run up to temp, checked for leaks – bone dry. Took it for a shakedown ride. Pulled strong, no smoke. Mission accomplished! Old Shadow got its heart back.