Pilot Engine Rebuild "Top to Bottom"

Rebuilding a Honda Pilot engine "Top to Bottom"

"Tools"

The first and most important thing you need to do before starting on a project of this scope is to read the manual thoroughly, and understand EXACTLY what you are getting into. The pilot motor rebuild requires special tools, and patience in order to do the job right!

Here are some pictures and descriptions of the special tools necessary for a pilot engine rebuild.

This is the flywheel puller. It is a compete MUST HAVE in order to keep from damaging the flywheel. It was ordered from RockyMountainATV the part # is 28-2037. If you can't find that part # it is a 30 mm female left hand thread with a 1.5 thread pitch.

A shop press of some kind or another is another tool thats hard to get by without

Here is a picture of a boring machine. Its not mine, but if your cylinder needs boring the best thing to do is find a reputable shop to do the work!

Here is a picture of a very nice hone. The stones on this hone are 6" long. The long stones prevent damage to the ports during the honing process. Forget flex type or ball hones.

This is a tool I built for PULLING the crankshaft into the cases. I got the Idea for this tool from Big Tom.

A heavy washer was welded to the end of a piece of 1-1/4" black pipe.

While hardly special, Hardwood blocks sure do come in handy!

Here a picture of the case assembly tool in action.

Its kind of hard to tell in this picture, but I am using the press and an appropriately sized round disk to press this bearing into place. The disk came with a seal and bearing press kit I got at Harbor Freight.

This is a 12 x 14" piece of 3/8" plate glass with a piece of 400 grit sand paper taped to it. This and a can of PB Blaster makes a great improvised lapping plate.

After you get everything back together its important to do a leakdown check to ensure that everything is sealed up tight.

This list shows a lot of tools. There are a few more that you might need. Without access to this stuff, rebuilding a pilot motor will take longer, and you run the risk of damaging an expensive or non-replaceable part.

The rebuild is broken into 4 sections. Refer to each section as needed for details on that part of the procedure
"Top to Bottom" Home	Parts	Disassembly	Inspection	Reassembly

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Opinions expressed within are those of the author or the quoted source. The author is not a professional machinist, mechanic, or engineer; no information provided herein represents professional advice or best practices. All information is provided to help hobbyists and other non-professionals gain a better understanding of the procedures, tools and techniques described. Considerable care has been exercised to provide accurate and timely information. However the author cannot be responsible for information which is incorrect or out of date. All practices, procedures, modifications and product recommendations described herein are to be used at the discretion and risk of the reader.

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Here are some pictures and descriptions of the special tools necessary for a pilot engine rebuild.
This is the flywheel puller. It is a compete MUST HAVE in order to keep from damaging the flywheel. It was ordered from RockyMountainATV the part # is 28-2037. If you can't find that part # it is a 30 mm female left hand thread with a 1.5 thread pitch.	A shop press of some kind or another is another tool thats hard to get by without
Here is a picture of a boring machine. Its not mine, but if your cylinder needs boring the best thing to do is find a reputable shop to do the work!	Here is a picture of a very nice hone. The stones on this hone are 6" long. The long stones prevent damage to the ports during the honing process. Forget flex type or ball hones.
This is a tool I built for PULLING the crankshaft into the cases. I got the Idea for this tool from Big Tom.	A heavy washer was welded to the end of a piece of 1-1/4" black pipe.
While hardly special, Hardwood blocks sure do come in handy!	Here a picture of the case assembly tool in action.
Its kind of hard to tell in this picture, but I am using the press and an appropriately sized round disk to press this bearing into place. The disk came with a seal and bearing press kit I got at Harbor Freight.	This is a 12 x 14" piece of 3/8" plate glass with a piece of 400 grit sand paper taped to it. This and a can of PB Blaster makes a great improvised lapping plate.
After you get everything back together its important to do a leakdown check to ensure that everything is sealed up tight.	This list shows a lot of tools. There are a few more that you might need. Without access to this stuff, rebuilding a pilot motor will take longer, and you run the risk of damaging an expensive or non-replaceable part.