Four Wheel Forum

Tonight I assembled the cam and adjusted the valves in order to finish assembling the Benly 150 head. I also had to paint the last engine part which was the tachometer cover which was needed to hold the one side up of the camshaft which is needed before you can adjust the valves. These are the last steps before installing the cylinder.

Now I have to be careful to put the right number of guides back into the cylinder holes before I attempt to slide the cylinder back down onto the transmission. Of course I need to install the piston rings on the CA95 pistons so I can check them and file them down if needed. I made sure to oil the cylinder down as soon as I got it back so the raw iron wouldn't start rusting on the spot. Basically I just am double checking everything and tomorrow morning after a cup of coffee I'll be putting the Benly engine together. I can't wait to see what it looks like all in one piece! Here is a couple Benly 150 engine pictures.





I have detailed pictures of taking both engines apart so after viewing these I'll have no doubts about how many guides there are and exactly where they go.

After consulting the ca95 parts manual and using my discerning memory I sketched an exact diagram of where the cylinder guides and o-rings should be placed as the cylinder is assembled.



Once that stuff is done the engine looks like this:

Ok since I've got a couple requests to show everyone the secret to putting the CA95 engine together, here are the details. Well it's actually no secret at all but looking up the assembly procedure in the books is a pain in the butt. Just look at the pictures and everything is explained... easy stuff!

Make sure you place all the guides and rubber o-rings back around the guide rods. These are kinda tricky to remember where they went and it was the main reason for my little hand drawn diagram that you see above in this thread. They don't go around all the guides at all.


The CA95 timing gear only goes on one way. As you can see, the two bolts at the bottom are closer together then they are to the top one. Before I take chains off I always mark them just to make sure things are correct when I assemble them again. You can see the marked top link on the sprocket.


Here are the timing marks where they should be when the timing gear is at the "12 o-clock" position (which ISN'T exactly Top Dead Center).


And here we are all together with the chain installed correctly. Now the only adjustment left is the points apparatus but that is adjust when everything is together and running.


See? As easy as putting together a lawn mower engine.. or Harly Davidson.

my pistons wouldnt free up the way you said. so I had to take the timing parts off and the chain master link was dead balls on the bottom as I figured. Do I have to put the marked spot of the chain back to its original piont? So the master link is on the bottom again or does it matter when I reassemble everything again? another thing...is it worth painting and do you need a high temp paint like 1600 degree paint?...powder coat or paint ? im thinking just clean it up

Crap I didn't see your question pop up back in April, sorry for the delay. Yeah it's easy to drop parts down there when you're taking things apart. As long as the timing marks line up it doesn't matter where the master link of the chain is when you assemble it.

You can use spray paint that you would find down at any hardware store. The engine never gets hot enough to boil regular engine paint off at all. You can get glossy engine paint and everything. If you want it to shine use another coat of clear. If you go to a auto parts store you will see all kinds of paint for this. Powdercoating is a waste on these engines and you''ll have to completely strip it down which will take you days. And I haven't really seen powdercoating hold up to engine heat too well. Maybe the flat or krinkle coat DuPont but if you use a glossy or especially a clear you will get discoloration form the heat over time. From my experience anyways. If anyone knows of a special brand that doesn't fade or discolor under this kind of engine hear or abuse I would like to know.

Also here is my thread about painting my engine: http://www.fourwheelforum.com/showthread.php?t=102