Time to clean up and put things back together! No real surprises here, Honda made it fairly straight forward to re-assemble the bottom end. The crankcase splits horizontally allowing one to assemble the transmission’s shift drum, forks & gears, balancer shafts, and crankshaft, and lay them all down in the lower crankcase before closing everything with the upper crankcase. Then install the clutch and align the front and rear balancers and things start looking promising. Funny thing is that there is always a short moment of self-doubt were one wonders if every part was really in place and if something was forgotten. Probably like a doctor counting all his tools after completing a surgery and making sure that he didn’t forget any instrument in the patient! Nah, we’re good.
The intend has been to rebuild the bottom end as an XR500. I inserted though the neutral (gear) position indicator from the XL just in case I decide to use the XL left engine cover and its corresponding neutral switch sensor. Then again, who needs a bright neutral light indicator on a dashboard?!
Now that the bottom end is back together, let’s go crazy with paint!