AZ 2005 build - Are you ready for another one?

Well after driving to Illinois (Almost 1,500 miles - took three days to get there) for a family emergency, (Left on the 14th) I stayed, until the 25th, leaving Chris there to help out my son and his family, until he fully recovers, I drove back in two days. I did 830+ miles on the first day and the rest on the second day. One issue we had on our way there was getting over the 10,500 ft & 11,200 ft passes just west of Denver. They were caked in ice, while it was snowing. I put my Tacoma into 4x4 mode and we drove right through it all. A number of big rigs and non 4x4 vehicles we stuck on the side of the road. But we were glad to get through it without any issues.

Now that that's out of the way, back to the bike!

Today, I played musical chairs with the 2004 & the 2012. I sent the 2004 out to the tractor shed, and moved the 2012 by the shelves. That gave me the room I need to be able to work on the bike without having to move my truck out of the garage and the 2012 to where I park the Tacoma.

With that taken care of, I finally got back to the bike. My task today was to reinstall the rear tire and prep it for a sponge bath. That may not happen tomorrow, depending when the rain will hit. I also need to park the engine back up on the lift, so I can get to it. I'll then park the frame where I was parking the 2012.

Got all of that? :rofl1:

Here's the AZ2005 ready for the bath:

20250331_Washrack3.jpg

20250331_Washrack1.jpg

Where the bins are sitting to the right of the picture, is where the frame will sit while I work on the engine.
 
I moved the frame to the side and used the tractor to move the engine on to the lift!

Due to weather, I didn't give the frame a bath, I'll wait for warmer weather. But now I can start on the engine!

20250401_EngineOnLift.jpg
 
That's a good day, the water pump install is a bit challenging and very satisfying when done.
Don't pinch the seal, ha!
 
Sidekick said:
That's a good day, the water pump install is a bit challenging and very satisfying when done.
Don't pinch the seal, ha!
Click to expand...

With a press, it makes it a lot easier, but coming up with the different things to get everything pressed in, took some time to come up with.

At one time, when I did two in a month, the second one was easy. But that was 5 years ago. :unsure:
 
Today's progress went a little slow.

I was able to install the Alternator & Starter.

20250403_Alt-Starter.jpg

I then pulled the clutch on the 06 Cop engine. Actually it's about what I figured. Burnt to a crisp!

20250403_CopClutch-burnt.jpg

So I looked at the original AZ05 clutch and it was worn, not unusable, but the other clutch I have is in much better shape.

20250403_good clutch.jpg

But I need to pick up the 30mm twelve point socket to break loose the basket nut and get a new basket nut to replace it. I'll try the local Honda Dealer and see what they have or have to order. As for the socket, I'm not sure....
 
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Okay, more progress!

Thanks to Larry ( @Igofar ), finding out what size the clutch basket nut is, I was able to pick one up, on my trip (12 point - 30mm). I tried to loosen the one on the 05 engine, but since I didn't have it secured properly, it wouldn't come loose. Today, I was able to break loose the 06 nut, which is the one I really needed loose anyway. The outer basket isn't all burnt up like the inter basket is, so I might use it, if I can't get that 05 loose.

20250412_ClutchBasketNutRemoved.jpg

Also, I replaced the clutch slave and other seals and o-rings on the rear cover.

20250412_RearCoverDone.jpg

When I removed the 06 clutch slave, I was expecting a real mess, like most of them. Obviously, some one "recently" had replaced it. If I ever need another one, I'll just get the rebuild kit, to make sure the seal didn't go bad, since I was always loosing the clutch, when I tried to start it.

20250412_ClutchSlave-06.jpg

So, next week I'll see about getting the clutch, water pump and cover, all back together.
 
Are you talking about the oil starved AZ 06?
Not sure who could’ve replaced that clutch slave cylinder recently……
 
Igofar said:
Are you talking about the oil starved AZ 06?
Not sure who could’ve replaced that clutch slave cylinder recently……
Click to expand...

Hey Larry, The AZ 06 is the ex cop bike. The AZ 05 is the bike I picked up through you.

The ex cop bike's engine, is the one replacing the 05's, ran out of oil engine. ;)

So, yes, I'm amazed that someone had replaced the ex cop bike's clutch slave.
 
When I was removing the Knock sensor connectors, the one on the right side of the engine was melted. So I replaced the wire harness to the knock sensors, and while I was installing the new harness, I decided that swapping the sensors with the 05 sensors would be a good thing. So here is the sensor (on the right) of the 06 and the one on the left is from the 05.

20250424_KnockSensors.jpg

The right side of the 06, looked pretty much like the sensors from the 05. That right side on the 06, must have gotten pretty hot!

Tomorrow, I'll continue with the wiring and then start of the coolant lines & thermostat.
 
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