Before I do this for the first time, any of you oldtimers highly experienced RD enthusiasts have any essential do's and/or don'ts as I get this fully refreshed motor back together? Just looking for any "make sure you do/don't do this" kind of hacks or warnings to limit the chance I do something dumb or help make things easier. Also, 12 year old opened tube of Yamabond4 or a new unopened tube of Hondabond4? I'm inclined to go with the Hondabond semi-drying just 'cause it is new, guessing these sealants can break down over time. Motor pics before assembly and after paint, I am really digging the satin black!
Use the new sealant.
Also, dry fit the cases and make sure everything lines up. Shift through the gears and make sure you get all 6. I assembled and installed my motor once after checking first, neutral and second.
Never got third and it felt horrible when I tried. Motor came back out and I had the shift fork in the wrong spot.
So, don't do that.
Make sure your base gaskets don't overlap each other. Use Yamaha gaskets on the motor when you can.
thanks striker, i'm on board with all of that and excited to start putting this thing back together. it will have to just sit for a bit once together while i build up/out the chassis but i just have to enjoy looking at it on my counter until then.
I can add that make sure the nubs on the crankshaft main bearings are positioned properly in the pockets of the lower case and you have the C shaped bearing retainers in place, 1 on the crankshaft, 1 on the trans bearing by the chain sprocket, and a little one on the other end of that trans shaft.
'76RD, that brings up an interesting point which is the new vito's crank i am installing does not have the nubs which seemed odd at first. rather it has o-rings aligned with where those nubs line up on the bearings and that's the mechanism that keeps the outer part of the bearing stationary once the cases are back together. And thanks for the note on the bearing retainer rings, yup those are all positioned correctly and ready.