engine torn down... What a mess!

[Re-run]

I like a paper manual too. I just prefer paper in general to reading a screen. Not sure why.
What I do, if I need to reference the manual and have some time, I print off the section I need when at work. I suppose I could do a few pages a day and over time have a paper manual!

[dave Esch]

I thought I would post some pics of the motor in progress. Why? I don't know. Sheer excitement I guess. I got the new rings in today and managed to finesse them into the jugs. I also got the new valve seals in and reinstalled the springs. So much easier to do than a car. Tomorrow I will start putting the head and valvetrain back together.

[TOOLS1]

Been awhile since I seen a striped engine. Now I'm getting excited It is pretty. I see you have placed it upon the alter to the Snap-on God's.
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[dave Esch]

it looks so much better than the flaked spray paint that was on it. I also couldn't believe that with the amount of crap I got out of that motor that it even ran at all. I am continually impressed with this bike. Best $1500 I ever spent.

[TOOLS1]

These things will run with used deep fryer oil, and metal fillings.
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[dave Esch]

i HAVE A QUESTION. I put the jugs on and was going through the manual trying to find a diagram of the head to cylinder parts. Basically which bolts get grommets and which get o-rings. I can't find one in 2 different manuals. BUT, whilst on this quest, I saw a diagram of the block to cylinder surface and realized that there are 4 large rubber o-rings that go around the pistons. I didn't put these in but I do have them. The reason I didn't install them was because I didn't take any off during disassembly. Either they were never put on or I don't need them for this motor. Any suggestions? Also, I suppose this could explain the front oil leak. I suppose it's possible the old o-rings were just fused to the gasket and I didn't notice them. But I think I'd remember pulling them off around the pistons. THis sucks! I hate to pull the jugs back off. They weren't easy going on, but obviously I will if needed.

[dave Esch]

Took the jugs off and found where the o rings go. Now for these grommets. I am at a loss. No pics of them in either manual. i HAVE 8. i BELIEVE THEY GO UNDER THE HEAD AROUND THE STUDS.

[Re-run]

I am almost positive they go around the studs. I will see what my manual say on the matter.

[dave Esch]

yEP. hEADS ON. tHE 4 LARGE o-rings were around the bottom of cylinder bore. The grommets go around the studs and the dowells are inserted into them. The heads on, torqued down. About to start reassembling valvetrain. Thanks.

[dave Esch]

Ok, progress was made. The motor work is complete. Adjusted valves. I had to look 3 times to verify the valve clearance. 0.002 and 0.003" just didn't seem right. THat's tight!!! My stainless bolts are in also. I should have the motor ready to go back in the bike by this weekend. With any luck she'll be running by next weekend.

[Re-run]

I have taken to increasing the gap by .001 on each side. Maybe slightly more valve noise but things will last longer. I have not done it with a fresh engine so I will not say to do that with yours as .002 and .003 have worked in the past and I don't know what would happen. I run mine that way right now.

[dave Esch]

The engine is mounted and I have started piecing her back together. My first snag is this clutch cable. I purchased a new one because the clutch was very hard to pull and I found that no amount of lube would free it up, even with both ends of the cable detached. Unfortunately, I only did a visual comparison of the two cables before throwing the old one away. Now I can't seem to dial the new cable in. Where the cable goes through the cover I have a collar nut, a nut, and then the cable. All of which I assume adjusts tension. But the collar does not fit into the cover. So when I let go of the clutch lever, the collar moves about 1/16" away from the hole. When I squeeze it again it pops into place with a click. Is this the wrong cable ya think? It looked identical to the old one. Also, even with the new cable it is much harder to pull than any other bike I have ridden. Is it just the style of the clutch mechanism? Are all these bikes like this?

[TOOLS1]

I don't have a clutch, so I don't know, but maybe you have heavy duty clutch springs.
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[dave Esch]

Well I am off to buy oil. I should be attempting to start the bike in the next hour or so. Before I do, there is a hose clamped to my center stand. Looks like some kind of drain or vent. The only possible place I can find to put the other end is a small hole in the back of the engine. Still haven't figured out the clutch. But I'll wait until after I hear it run before I go into all that.

[dave Esch]

Well after filling one tank with oil and the other with gas, I installed the new battery and let the fuel on for a few minutes. The engine cranked for about 5 seconds and then sputtered to life. It sounds very, very strong. A huge difference from how it sounded last year. I may be imagining things but i do believe the bike revs up and down much faster too. Also it isn't blowing smoke. What I do notice is if I spike the throttle the bike dies out and then picks up, but revs slowly very nicely. I adjusted the needles two notches leaner and planning to have the carbs synched. But I have to wait until my front caliper piston comes in the mail. The AGONY OF WAITING!!!! I'll post pics later.

[TOOLS1]

Here you go http://cgi.ebay.com/ebaymotors/Carb-Sync-Mercury-Tuner-W-5-6mm-adapters-CAR-_W0QQcmdZViewItemQQhashZitem588de51866QQitemZ380337723494QQptZMotorsQ5fAutomotiveQ5fTools I bought my gauges off this guy, for $45.00, but all I can find now is the mercury ones. They are supposed to be better though. Or you could ask the guy if he still has the gauges. It's a lot cheaper then taking the bike to a shop.
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[dave Esch]

The purchase price of the gauges was $39. The shop that is doing it will charge me $45. They specialize in the CB bikes. Custom bobbers and cafe's and the like. So this is probably one time I will pay someone else. I am probably able to do it myself, but when it comes to carbs, I'd trust the pro's.

[dave Esch]

Here is a pic of the "just about" finished project.

[TOOLS1]

Looking good. Can I ride it?

[dave Esch]

If you want to ride with no brakes