Important rebuild tools

[redstrat]

Over the past six months I have purchased 3 and 1/2 125 Force motors (1986-1989). Most of them I acquired by trading upholstery services. All of these motors are in various states of disrepair. After reading in this forum for these past few months I am impressed and thankful for the knowledge you guys share. I have a Force manual and a good assortment of hand tools. My question is... what specialty tools should be on the top of my list for complete rebuilds? Also, how do I pick a good machine shop for boring and honing? Thanks in advance for your input.

 

[Frank Acampora]

Re: Important rebuild tools

First on the list, make your own flywheel puller or buy a harmonic balacer puller. Three jaw gear pullers just don't do the job. Second, buy a good quality INCH POUND torque wrench capable of up to about 250-300 inch pounds. An air impact wrench sometimes can be handy in cracking off the flywheel but for most jobs is not a necessity.

You will most likely break off screws and a high quality cobalt steel drill bit set and a couple of taps is a must.

A couple of decent sized prybars are necessary to remove powerheads from engine legs. A small to medium press is very helpfull in removing wrist pins and con rods. Additionally, if you will be using stock replacement pistons you will need a special tool to space the small end bearings. If you use aftermarket pistons with the wrist pin retained by circlips, then this tool is not needed.

To find a good machine shop for boring, search out shops that do hi-po auto engines or someone who specializes in outboards. ---Even though the bottom of the cylinders are open, the bearing mounts pass across. Thus: the boring bar and hone can not pass all the way through the bore and these engines are considered closed bore engines. It does take a little extra skill to bore and hone them correctly.

 

[spool]

Re: Important rebuild tools

Speaking from experiance you will need a few helicoil kits aswell, some of the original threads will
Come out with the bolt.

You will also need a 1/4" multihex socket for the conrods and a can of thread delocker.
I found by far the best way to remove broken bolts with is with a pair of vice grips.

 

[redstrat]

Re: Important rebuild tools

Thanks for the tips, I have tried searching the web for the special tools listed in the force manual with no luck. Any ideas on how to locate the suggested shim tool? I'm trying to spend my limited resources on the right tools before I start buying parts. Thanks

 

[Frank Acampora]

Re: Important rebuild tools

The tool I showed is not available BUT: if you enlarge the photo, you can see the details and the sizes are stamped into it. It would be very easy to make. The .290 side is for removal and the .310 side is for installation.

 

[redstrat]

Re: Important rebuild tools

Thanks Frank, I see what you mean.

 

[spool]

Re: Important rebuild tools

The tool I showed is not available BUT: if you enlarge the photo, you can see the details and the sizes are stamped into it. It would be very easy to make. The .290 side is for removal and the .310 side is for installation.

As Frank would know, the spacer tool is only useful if you intend on reusing the needle roller bearings. We pressed the pins out without the shim tool as i had purcahsed new Wiseco pistons and bearings and was only reusing the conrod.