This Honda Elite 80 (CH80) has a blown engine engine - Can we save it?

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The Honda Elite 80 is one of the best selling and most produced scooter in the United States. So it was only a matter of time before one showed up in our shop with a blown engine. This particular scooter had served its owners for well over 11,000 miles but a catastrophic engine failure landed it in our shop.

The first step was to check the baseline of the engine. A compression test confirmed something was seriously wrong. The Elite's engine was only producing about 15 psi of compression. Thats WAY under the 150-180 psi a healthy engine produces.

After removing the engine the valve train was inspected for a bent or burned valve. The cylinder head was then removed and we discovered the piston had a dramatic amount of movement inside the cylinder bore. After removing the cylinder we found that the piston had completely shattered!

A thorough inspection of the bottom end found that the crankshaft, crank bearings and connecting rod were still in good shape. So we fished out the piston pieces with a pair of chop sticks and proceeded to rebuild the top end.

The final speed bump was discovered when decarbonizing the head. The intake valve had been damaged on the sealing surface so a new valve had to be ordered and installed.

The first start of the rebuilt engine took place on a very cold (by texas standards) 32 degree day. After a few attempts with a pretty weak battery the engine roared back to life.

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#Honda #Scooter #Elite