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JPWilliams
02-13-2010, 4:05 PM
EDIT : Don't use Facebook for image hosting. My earliest stuff has all fallen victim to broken links. I redid this write-up here. http://tearitupfixitrepeat.blogspot.com/p/v-behaviorurldefaultvml-o.html I cleaned it up and organized a bit better. I'm not trying to take away from chopcult. I just wanted to share the info


You guys asked for it so here goes.

Getting started.

http://hphotos-snc3.fbcdn.net/hs143.snc3/17031_1257415028070_1010435000_30645795_7365771_n. jpg

That's my friend "Hot Sauce" with a quick cup of inspiration,

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1257415068071_1010435000_30645796_3837691_n. jpg

Tank and seat gone. Hot Sauce goes too fast to get good action shots.

http://hphotos-snc3.fbcdn.net/hs123.snc3/17031_1257415148073_1010435000_30645798_5242194_n. jpg

Pipes in the pile.

http://hphotos-snc3.fbcdn.net/hs143.snc3/17031_1257415188074_1010435000_30645799_192727_n.j pg

Drain the anti-freeze.

http://photos-h.ak.fbcdn.net/hphotos-ak-ash1/hs243.ash1/17031_1257415228075_1010435000_30645800_840628_n.j pg

Left board gone.

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1257415268076_1010435000_30645801_2126626_n. jpg

Right board gone.

http://hphotos-snc3.fbcdn.net/hs123.snc3/17031_1257415308077_1010435000_30645802_5561516_n. jpg

Hot Sauce unplugging the electronics.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1257415348078_1010435000_30645803_4678161_n. jpg

Hey, let's drain the oil!

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1257415388079_1010435000_30645804_6249141_n. jpg

Up on the jackstands now.

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1257415468081_1010435000_30645805_1940868_n. jpg

Subframe piece off....

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1257415508082_1010435000_30645806_7021967_n. jpg

Engine on the jack and disconnect the driveshaft.

http://hphotos-snc3.fbcdn.net/hs123.snc3/17031_1257415548083_1010435000_30645807_196234_n.j pg

Big pry bar to move the jack sideways a bit.

JPWilliams
02-13-2010, 4:08 PM
http://hphotos-snc3.fbcdn.net/hs123.snc3/17031_1257415588084_1010435000_30645808_6561593_n. jpg

Engine is offically disconnected.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1257415628085_1010435000_30645809_141145_n.j pg

Engine on the ground in just under 2 hours.

http://photos-g.ak.fbcdn.net/hphotos-ak-ash1/hs243.ash1/17031_1257415668086_1010435000_30645810_4894346_n. jpg
http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1257415708087_1010435000_30645811_2121978_n. jpg

Big hole.

http://hphotos-snc3.fbcdn.net/hs143.snc3/17031_1257415748088_1010435000_30645812_4811032_n. jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-ash1/hs243.ash1/17031_1257415788089_1010435000_30645813_4173708_n. jpg

On the rebuild cart.

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1257415828090_1010435000_30645814_6273671_n. jpg

Rocker box covers off, first.

http://hphotos-snc3.fbcdn.net/hs123.snc3/17031_1257415868091_1010435000_30645815_921819_n.j pg

Rear head. It was the noisy one, but nothing is obviously wrong.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1257415908092_1010435000_30645816_7849250_n. jpg

Front head looks okay.

http://photos-f.ak.fbcdn.net/hphotos-ak-ash1/hs243.ash1/17031_1257415988094_1010435000_30645817_3996446_n. jpg
http://hphotos-snc3.fbcdn.net/hs123.snc3/17031_1257416028095_1010435000_30645818_2784317_n. jpg

Okay enough for one day, put your crap up.

nohonestlyitsme
02-13-2010, 10:56 PM
put that motor in a CB350 or bust. Ha im kidding... Or am I?

JPWilliams
02-14-2010, 7:02 PM
http://photos-f.ak.fbcdn.net/hphotos-ak-ash1/hs243.ash1/17031_1258623098271_1010435000_30647922_4723518_n. jpg
Let's get started.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1258623138272_1010435000_30647923_6540382_n. jpg

Rear oil line off.

http://hphotos-snc3.fbcdn.net/hs123.snc3/17031_1258623218274_1010435000_30647925_5733627_n. jpg

Start to take off the nuts from the rocker boxes.

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1258623258275_1010435000_30647926_4912435_n. jpg

GEEEEZZZ! The big ones are tight!

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1258623338277_1010435000_30647927_3034968_n. jpg

Not sure what is on these long ones, but when I pulled them something really smelled wierd.

http://hphotos-snc3.fbcdn.net/hs143.snc3/17031_1258623378278_1010435000_30647928_2327186_n. jpg

Just like whack-a-mole.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1258623418279_1010435000_30647929_5119254_n. jpg

Underside of the rear rocker box. I haven't done full testing yet, but I think two of the hydralic adjusters are weak.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc3/17031_1258623458280_1010435000_30647930_6399180_n. jpg

Rear cam exposed.

http://sphotos.xx.fbcdn.net/hphotos-ash2/17031_1258623498281_1010435000_30647931_4657719_n. jpg

Here's the rear compression release I was thinking was the source of the noise. Still not sure.

JPWilliams
02-14-2010, 7:11 PM
http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1258623538282_1010435000_30647932_2142566_n. jpg

Remove front oil line.

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1258623578283_1010435000_30647933_4226458_n. jpg

NUTZ OFF!

Whack-a-mole did get this one done so...
http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1258623618284_1010435000_30647934_671980_n.j pg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1258623658285_1010435000_30647935_1939658_n. jpg
there are two little pry spots I used. I hope that was what they were. There are two notches on both rocker boxes.

http://hphotos-snc3.fbcdn.net/hs143.snc3/17031_1258623698286_1010435000_30647936_866510_n.j pg
Front cam.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1258623738287_1010435000_30647937_6131621_n. jpg
Underside of the front rocker box. These hydraulics seems good.

JPWilliams
02-14-2010, 7:20 PM
Behind here ...
http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1258623778288_1010435000_30647938_292591_n.j pg
is the nut you can turn the motor with.

http://hphotos-snc3.fbcdn.net/hs123.snc3/17031_1258623818289_1010435000_30647939_5863381_n. jpg
There it is.

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1258623858290_1010435000_30647940_629307_n.j pg
I think the alternator cover should slide of the shift shaft, but I think my shift shaft is bent from some left side dumps. I'm not sure what if I'll replace this or not. I probably should though.

http://hphotos-snc3.fbcdn.net/hs197.snc3/20431_1258623938292_1010435000_30647942_4236743_n. jpg
Finally found the timing mark. Didn't look exactly like the book. It really shouldn't matter until I go back up, though.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs143.snc3/17031_1258623978293_1010435000_30647943_6318462_n. jpg
Taking the camchain tensioner off.
http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs123.snc3/17031_1258624018294_1010435000_30647944_6221295_n. jpg

JPWilliams
02-14-2010, 7:32 PM
Got the tensioners off and the cams out, but didn't a picture of the cams.

The spark plug tubes have to come out to get the heads off. It takes 27mm external hex. So off to ACE to get a bolt and two nuts $10.22. Sucks.

<a href="http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc3/17031_1258624138297_1010435000_30647946_5719369_n. jpg="_blank"><img src="http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc3/17031_1258624138297_1010435000_30647946_5719369_n. jpg" border="0" alt="27 mm Driver"></a>


Works!
<a href="http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc3/17031_1258624178298_1010435000_30647947_3696338_n. jpg="_blank"><img src="http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc3/17031_1258624178298_1010435000_30647947_3696338_n. jpg" border="0" alt="27 mm Driver"></a>

Yep, camchains were rubbing before I did those camchain extenders.

<a href="http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc3/17031_1258624218299_1010435000_30647948_6509191_n. jpg="_blank"><img src="http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc3/17031_1258624218299_1010435000_30647948_6509191_n. jpg" border="0" alt="Scored Tube"></a>


Both tubes.

Start again in the morning. I love Presidents' Day!!!

jpswino
02-14-2010, 8:53 PM
Real Cool. Got any plans to hop it up any?

JPWilliams
02-14-2010, 9:35 PM
Real Cool. Got any plans to hop it up any?

Afraid not. I could do a big bore kit from Thunder Manufacturing (http://www.thundermfg.com/store/index.php?l=product_detail&p=169), but if I had an extra $1250 to blow on bike parts it go to a springer for my shovelhead. http://www.chopcult.com/forum/showthread.php?t=2573

JPWilliams
02-15-2010, 1:05 PM
http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259272554507_1010435000_30649724_894219_n.j pg

Two cap nuts hold each head to the cylinder.

http://hphotos-snc3.fbcdn.net/hs197.snc3/20431_1259272634509_1010435000_30649726_131061_n.j pg

This one is hard to get at.

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs177.snc3/20431_1259272714511_1010435000_30649728_722977_n.j pg
Under side of the front head.

http://hphotos-snc3.fbcdn.net/hs177.snc3/20431_1259272754512_1010435000_30649729_8242150_n. jpg

Top of front piston.

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259272834514_1010435000_30649731_304634_n.j pg
Rear head coming off.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259272874515_1010435000_30649732_1732585_n. jpg
The inside nut is easier with one head removed.

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs177.snc3/20431_1259273074520_1010435000_30649736_1716455_n. jpg
Underside of the rearhead.

http://hphotos-snc3.fbcdn.net/hs177.snc3/20431_1259273114521_1010435000_30649737_5602783_n. jpg
Top of rear piston.

JPWilliams
02-15-2010, 1:15 PM
http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs177.snc3/20431_1259272994518_1010435000_30649734_5630225_n. jpg
Both heade gasket surface seam wet with antifreeze and the both head came off with out any effort at all. I wonder if the head gaskets were leaking causing the oil usage and/or the radiator boilover.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273154522_1010435000_30649738_5286095_n. jpg

Front camchain extensioner shoe.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273194523_1010435000_30649739_1327835_n. jpg
Rear camchain extensioner shoe.

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs177.snc3/20431_1259273234524_1010435000_30649740_4617264_n. jpg
Two nuts hold each cylinder on.

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs177.snc3/20431_1259273274525_1010435000_30649741_2190563_n. jpg

http://hphotos-snc3.fbcdn.net/hs177.snc3/20431_1259273314526_1010435000_30649742_4527696_n. jpg
Front Piston out.

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs177.snc3/20431_1259273354527_1010435000_30649743_4552719_n. jpg
Front cylinder on the table.

JPWilliams
02-15-2010, 1:23 PM
Rear cylinder.....
http://hphotos-snc3.fbcdn.net/hs197.snc3/20431_1259273394528_1010435000_30649744_1183076_n. jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273434529_1010435000_30649745_3786947_n. jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273474530_1010435000_30649746_4704085_n. jpg


http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273514531_1010435000_30649747_8335084_n. jpg
Both pisons hanging out of the crankcase, now we can really get to work!

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs177.snc3/20431_1259273554532_1010435000_30649748_6081075_n. jpg
Soak the piston tops in this stuff to soften the carbon.
http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273634534_1010435000_30649750_6861498_n. jpg

Cover everything and quit again.
http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273674535_1010435000_30649751_3265151_n. jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273714536_1010435000_30649752_24310_n.jp g

JPWilliams
02-22-2010, 8:13 PM
Here's what a leaky intake valve seal looks like.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/VulcanRebuild083.jpg
Here's what a really bad cam follower looks like.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/VulcanRebuild089-1.jpg
Here's the matching spot on the cam.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/VulcanRebuild092.jpg
Look at the rest of this cam and it's smoked.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/VulcanRebuild091.jpg

Both cams and all the followers are smoked.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/VulcanRebuild088.jpg

Fortunately I found a set of salvage heads from http://www.shermscycleproducts.com/ (http://www.shermscycleproducts.com/) Guy Mobbley really know his stuff on these engines.

http://www.shermscycleproducts.com/images/vn%201500%20heads%20009.jpg

JPWilliams
02-22-2010, 8:23 PM
Left side inner cover off onto the bench.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild098.jpg

That's the alt rotor. We couldn't get the penny-on-a-string to lock up the motor on this side so we had to use the penny on the clutch side.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild097.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild099.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild101.jpg
The other stator.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild102.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild103.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild105.jpg
There's the front cam chain.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild106.jpg
Sumthin's bent and sumthin's broke.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild107.jpg

JPWilliams
02-22-2010, 9:25 PM
Penny on a ribbon in the clutch gear.

http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild108.jpg

You actually don't have to take this bolt off to get the starter gear off.

http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild109.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild110.jpg

Getting the waterpump chain tensioner off.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild111.jpg
Waterpump chains
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild114.jpg

Lock the motor the other way to get this bolt.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild115.jpg

A little fuzzy, but there's the rear camchain.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild116.jpg

JPWilliams
02-22-2010, 9:27 PM
Bent camchain guide,
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild117.jpg

A camchain is not suppose bent this much sideways.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/inside%20sidecovers/VulcanRebuild118.jpg

philbey
02-22-2010, 10:31 PM
so from what I'm gathering here, you just dangle a penny in to lock up the gears so you can get a socket on to unbolt stuff? Good tip that one, just need me a copper coin (don't have them in Australia anymore)

JPWilliams
02-23-2010, 10:52 AM
Yeah, a penny in the gears is old trick on the Vulcans for replacing worn out clutch springs. Actually the Clymer manual calls for brass or copper washer, anything that is softer than the gears, but will lock it up. A copper washer should be easy to come by for you, about any auto parts store should have them for drain plugs. They are a little more expensive than a penny would be though. The nice part of using a washer is that you don't have to drill a hole for the string. YOU NEED TO ATTACH A STRING! Don't ask me how I know.

JPWilliams
03-05-2010, 8:41 PM
Okay you guys were right I couldn't do this project without chopping the thing up. So all the engine covers when to the powder coaters to get the "blasted aluminum" treatment.

I have pistons and rings and I ready to send them and the cylinder to the machine shop.

The rest off the parts are on order, now to get into those used heads that came in the mail.

http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild123.jpg

Early heads, no carb warmer connection.

http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild124.jpg

I'll rob this one off the my first heads so I won't need a different hose.

http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild125.jpg

Into the "new" front head
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild126.jpg

so far so good

http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild128.jpg

This cam is good.

http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild130.jpg

Now to get the valves out,
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild132.jpg
Bag and Tag!
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild133.jpg
Get it done!
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild134.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild135.jpg
Front Right Exhaust
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild136.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild137.jpg

JPWilliams
03-05-2010, 8:47 PM
Front Left Exhaust
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild136.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild137.jpg
Front Right Intake
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild142.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild143.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild144.jpg
Front Left Intake
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild145.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild146.jpg
Bare Front Head
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild147.jpg

JPWilliams
03-05-2010, 9:07 PM
Into the rear head
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild148.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild149.jpg

Cam is good, picture is fuzzy
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild151.jpg
Followers good.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild152.jpg

Rear Right Exhaust
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild154.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild156.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild157.jpg

Rear Left Exhaust
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild158.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild159.jpg

Rear Right Intake
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild161.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild162.jpg

Rear Left Intake
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild163.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild164.jpg
Rear bare head
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/rebuild/Used%20heads/VulcanRebuild165.jpg

JPWilliams
03-23-2010, 8:57 PM
I got my powdercoat done! Still waiting on the machine work.
http://hphotos-snc3.fbcdn.net/hs375.snc3/24025_1291180872195_1010435000_30717047_736215_n.j pg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs395.snc3/24025_1291180912196_1010435000_30717048_4205758_n. jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs395.snc3/24025_1291180952197_1010435000_30717049_6169012_n. jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-ash1/hs435.ash1/24025_1291180992198_1010435000_30717050_6445265_n. jpg
http://hphotos-snc3.fbcdn.net/hs395.snc3/24025_1291181032199_1010435000_30717051_1157759_n. jpg
Before they were chrome and now they are "blasted aluminum."
http://photos-a.ak.fbcdn.net/hphotos-ak-ash1/hs435.ash1/24025_1291181072200_1010435000_30717052_2897554_n. jpg

Randew2u
03-26-2010, 10:12 AM
I'm so glad you are posting this. Please show the build! I just bought a 97 VN1500A with a blown motor and need to do a complete. There are going to be lots of POG meltdowns that guys are going to pick up cheap and want to rebuild. You are the only one who is showing a rebuild, thanks!!

JPWilliams
03-28-2010, 1:36 PM
There are going to be lots of POG meltdowns that guys are going to pick up cheap and want to rebuild. You are the only one who is showing a rebuild, thanks!!

I'm not going to split cases which would be called for to properly fix a POG, but the JOG can be done with right side cover and clutch basket off.

I've been wondering if a guy could put early dual carb heads on to a late model 5 speed case. That could be interesting. The pipes would have to be custom for sure, but I'm wondering if the rest is straight bolt on.

JPWilliams
03-28-2010, 1:39 PM
Now if I get some 12 inch apes and my machine work done, I will be going back up.



http://hphotos-snc3.fbcdn.net/hs493.snc3/26946_1295065529309_1010435000_30724503_625853_n.j pg

JPWilliams
03-28-2010, 7:19 PM
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers001.jpg
I thought about leaving all the sound dampers out, so I would get a better "vintage" bike racket, but I guess I'll put them because the engine would probably sound like it was fixin' to come apart and scare me.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers002.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers003.jpg
Needs a sight glass.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers004.jpg
I oiled up the new sight glass seal and used a special seal "19 mm" driver.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers005.jpg
Good as new.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers006.jpg
Oil cap is still chrome, but I guess that's okay.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers007.jpg

JPWilliams
03-28-2010, 7:22 PM
'nuther damper
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers008.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers009.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers011.jpg
What are these three spacers?
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers010.jpg
Oh those go here. Let's do that part again.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers012.jpg

JPWilliams
03-28-2010, 7:31 PM
Here's the problem child. The stater shaft goes in this bearing, but the boss is loose and all jacked up.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers013.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers015.jpg
Here's the problem solver.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers014.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers016.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers017.jpg
Clean up the extra because I don't want any of that in my roller elements.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers018.jpg
Threads for starter damper were really rough, so I chased them.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers019.jpg
ACE was closed so I had to re-use these. I hope they don't have to come out again.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers020.jpg
This side is now good to go.

JPWilliams
03-28-2010, 7:39 PM
Other side.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers021.jpg
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers022.jpg
Let's figure were all the hardware goes first this time.
http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers024.jpg
Good to go!

Preview of things to come.(only less fuzzy in real life)

http://img.photobucket.com/albums/v74/jfnp52/Vulcan/sidecovers%20together/sidecovers025.jpg

JPWilliams
04-10-2010, 7:06 PM
Still waiting on the machine work, but I figured I would post something cause I was bored.

Here's the grips, bars, and clamp I'm going to use. They are very ugly, but free. I think they'll get the "blasted aluminum" powder coat, too.

http://hphotos-sjc1.fbcdn.net/hs365.snc3/23535_1305255504052_1010435000_30747894_7134925_n. jpg

I bought one of these, too.
http://img.auctiva.com/imgdata/1/2/3/0/2/2/4/webimg/329207381_o.jpg
I was thinking about mounting it to the top of a chopped off fender, but it may fit under it.

JPWilliams
04-12-2010, 9:05 PM
Let's get to valve lapping on the 1500 Vulcan re-build. Here's the before on the front cylinder.

<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459446725168148146" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8PZ3wPRLrI/AAAAAAAAADM/qsvWw6AJyKs/s1600/DSC01328.JPG" /></a>
Here are the valve seals. They have to go.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459446734238676386" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S8PZ4SB2daI/AAAAAAAAADU/z7kC-mlLBy4/s400/DSC01329.JPG" /></a>
Pry 'em off and throw them away.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459446743222862418" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8PZ4zf2QlI/AAAAAAAAADc/-QJeWrhyIEQ/s400/DSC01330.JPG" /></a>
Get the lapping compound.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 300px; HEIGHT: 400px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459446752751438882" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8PZ5W_ozCI/AAAAAAAAADk/BWSaiNBXZ24/s400/DSC01332.JPG" /></a>
Put a light coat on the valve sealing area.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459446763100955234" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8PZ59jJ4mI/AAAAAAAAADs/dU9_nrRQJqE/s400/DSC01333.JPG" /></a>

Put the valve in to the hole it came out of and twist it back and forth, back and forth.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459447906396462322" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8Pa8gqC3PI/AAAAAAAAAD0/PxCRDvkHi24/s400/DSC01334.JPG" /></a>
When you clean off the compound and see a nice even gray line in the seat, you're good to go.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 300px; HEIGHT: 400px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459448083132045250" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8PbGzDF18I/AAAAAAAAAD8/d9K0Bq7C33U/s400/DSC01335.JPG" /></a>
You need a nice line on the valve, too.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459448231890264034" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8PbPdN0H-I/AAAAAAAAAEE/fAaEyLovR6k/s400/DSC01337.JPG" /></a>
Repeat that three more times and the front is done, but be sure to wash everything to get the compound off before you build the motor.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 300px; HEIGHT: 400px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459448454636888098" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8PbcbAv4CI/AAAAAAAAAEM/iL6pmLUtvy8/s400/DSC01338.JPG" /></a>
Repeat that 4 more times and the rear is done, too.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/vulcan-1500-valve-lapping.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5459448641154204418" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8PbnR18QwI/AAAAAAAAAEU/enzSl49hvTY/s400/DSC01341.JPG" /></a>

JPWilliams
04-12-2010, 9:47 PM
I found pictures of the wrecked fender that I'm going to chop off short or is it bobbed off?
http://img.photobucket.com/albums/v74/jfnp52/Fender/100_0070.jpg
http://img.photobucket.com/albums/v74/jfnp52/Fender/100_0071.jpg

JPWilliams
04-17-2010, 8:48 PM
Here's how to bypass the carb warmer. Get someone weld up the little tubes. I need to paint those still.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461292806937245058" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8po32vj9YI/AAAAAAAAAI4/RcGOAHwb47c/s400/DSC01365.JPG" /></a>
Remember me writing that the heads needed to washed after the valve lapping? Well here you go. I would normally do this outside, but it was rainy and I did it inside. I washed my little gas can too, because I want put in the back of the van just in case.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461292797477177874" border="0" alt="" src="http://4.bp.blogspot.com/_7WfR_akYPWo/S8po3TgGyhI/AAAAAAAAAIw/ERCBXU9b-Gg/s400/DSC01367.JPG" /></a>
The cylinders are back from the machine shop and they need washed, too.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461292414364674274" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8pohAS96OI/AAAAAAAAAIo/uugM7zZ7urc/s400/DSC01368.JPG" /></a>
Do you see the different surface finish? These were still a touch out of round even after the oversize. You can see, but not feel it. It is under where the rings will run so hopefully everything will be okay.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 300px; HEIGHT: 400px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461292407789104274" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S8pognzOrJI/AAAAAAAAAIg/qYS2mLBN_h4/s400/DSC01370.JPG" /></a>
After washing the cylinders, all of the steel parts need to be oiled to keep them from rusting until I get the motor together.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461292405348893442" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8pogetcAwI/AAAAAAAAAIY/3zvGWrnF_MU/s400/DSC01371.JPG" /></a>
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461292394152765906" border="0" alt="" src="http://4.bp.blogspot.com/_7WfR_akYPWo/S8pof1AEqdI/AAAAAAAAAIQ/Thvv0vNPWfs/s400/DSC01372.JPG" /></a>
Wash the heads.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461292386641801826" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8pofZBUcmI/AAAAAAAAAII/uu-zAADM_-w/s400/DSC01373.JPG" /></a>
Rinse the heads.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 300px; HEIGHT: 400px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461291475702996386" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8pnqXglXaI/AAAAAAAAAIA/pWhCG07umEc/s400/DSC01374.JPG" /></a>
This was something I hadn't noticed yet. The rear head has a basketweave in the casting...
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461291467439467842" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S8pnp4uZ7UI/AAAAAAAAAH4/Vk-RQz3vDAA/s400/DSC01375.JPG" /></a>
the front cylinder is smooth.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461291454649516322" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8pnpJFCwSI/AAAAAAAAAHw/xqUNOaZLVGk/s400/DSC01376.JPG" /></a>
Blow dry the heads to get the water out of the crevices.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461291446395591954" border="0" alt="" src="http://4.bp.blogspot.com/_7WfR_akYPWo/S8pnoqVJ3RI/AAAAAAAAAHo/3tMMcgm-5pg/s400/DSC01377.JPG" /></a>
Wash the valves.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461291438582195474" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8pnoNOS5RI/AAAAAAAAAHg/Woc1GOb88xU/s400/DSC01378.JPG" /></a>
Don't put those back in the bag wet or things will get ugly.

Now let's put the valves back in. Oil it up.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290634925968786" border="0" alt="" src="http://4.bp.blogspot.com/_7WfR_akYPWo/S8pm5bXuDZI/AAAAAAAAAHQ/k699soIHgw8/s400/DSC01380.JPG" /></a>
Put it in the head.
<div><a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290626303127650" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8pm47P38GI/AAAAAAAAAHI/yquF9eKVqhk/s400/DSC01381.JPG" /></a>
Oil the seal.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290640775939090" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S8pm5xKdhBI/AAAAAAAAAHY/PWeE4KDncB0/s400/DSC01379.JPG" /></a>
Put the seal on.
<div><a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290617496253042" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S8pm4acJsnI/AAAAAAAAAHA/nu6QnwW1PjM/s400/DSC01383.JPG" /></a>
Put the springs and retainer on with the tool.
<div><a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 300px; HEIGHT: 400px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290612988906610" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8pm4JphDHI/AAAAAAAAAG4/x2hc8WIszUI/s400/DSC01384.JPG" /></a>
Get the split keepers ready.
<div><a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290055601635058" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S8pmXtOCPvI/AAAAAAAAAGw/q2dMPggOWmg/s400/DSC01385.JPG" /></a>
Work those in.
<div><a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290046960180114" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S8pmXNBwG5I/AAAAAAAAAGo/DSSiS90MJfc/s400/DSC01386.JPG" /></a>
Take the tool off and one valve is done.
<div><a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290037447965234" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8pmWpl3OjI/AAAAAAAAAGg/KnElDK6e2Qw/s400/DSC01387.JPG" /></a>
Do that three more times and the rear valves are done.
<div><a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 300px; HEIGHT: 400px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290029484948306" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S8pmWL7VO1I/AAAAAAAAAGY/ZhI6TNo-yGo/s400/DSC01390.JPG" /></a>
Now do it for the front, and the valves are all done.
<div><a href="http://tearitupfixitrepeat.blogspot.com/2010/04/washing-and-installing-valves.html"><img style="WIDTH: 300px; HEIGHT: 400px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5461290018360426162" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S8pmVifCfrI/AAAAAAAAAGQ/qoejVuR2u38/s400/DSC01391.JPG" /></a>









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xpunkindrublicx13
04-19-2010, 11:20 AM
I'm so glad you are posting this. Please show the build! I just bought a 97 VN1500A with a blown motor and need to do a complete. There are going to be lots of POG meltdowns that guys are going to pick up cheap and want to rebuild. You are the only one who is showing a rebuild, thanks!!
I'm sure that they rectified the problem between '97 & '03, but when you do the rebuild on your '97, you will want to pay very close attention to 2nd & 3rd gear on the counter (output) shaft. The dogs on the slider and slots on the freewheeler have a tendency to round off, causing you to slip back into neutral after shifting into 2nd and applying throttle. I've done a couple of these, exact same year, model & problem 1997 VN1500.
By the way JP, nice thread and rebuild. Excited to see the finished product. really diggin the blasted alum.

JPWilliams
04-19-2010, 4:37 PM
I'm sure that they rectified the problem between '97 & '03, but when you do the rebuild on your '97, you will want to pay very close attention to 2nd & 3rd gear on the counter (output) shaft. The dogs on the slider and slots on the freewheeler have a tendency to round off, causing you to slip back into neutral after shifting into 2nd and applying throttle. I've done a couple of these, exact same year, model & problem 1997 VN1500.
By the way JP, nice thread and rebuild. Excited to see the finished product. really diggin the blasted alum.

Yes, I had this problem with my '03 in '05 with 35,000 miles on it. The dealer did a real shitty and long rebuild and I had to get an attorney to get Kaw to cover it under warranty. The thing has used oil like crazy since that rebuild and then the rear head when to making wierd noises. Lessons learned, nobody wreches on my bikes, but me, because I'm the only one who cares. I wasn't nearly as brave, mechanically speaking, five years ago either.

There's going to be a lot more powder coated than just the engine covers when I get this thing really the were I want it. I'm feeling pretty inspired with this one for sure.

xpunkindrublicx13
04-20-2010, 6:08 PM
That sucks that you had to get legal with it, but at least it got warrantied. I'm very surprised that they didn't make the gears better or do something to make those last longer. It ends up being quite a costly bill to the consumer for something that kawi could engineer a little better. Anyway best of luck on the rebuild, I'm staying tuned for sure.

NHMike
04-20-2010, 7:22 PM
Awesome thread. I love the blasted aluminum, looks killer! I had a VN800-A and I loved it. Great running machines!!! Can't wait to see this bad boy going!!

JPWilliams
04-21-2010, 9:06 PM
It's bad to high jack my own thread, but here's a buddy's 800 that he just finished.
http://forums.delphiforums.com/n/mb/at.asp?webtag=PlainsVROC&guid=18B93ED5-EE40-48A8-AD4C-9DF1B1BEBFF0&frames=no
http://forums.delphiforums.com/n/mb/at.asp?webtag=PlainsVROC&guid=0100167B-A473-4570-91A5-064C19F8C578&frames=no

One of kind exhaust, home built side mount tag, Crossbones take-off seat.

JPWilliams
04-29-2010, 8:49 PM
http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html


Just pull them out with pliers.

<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465736046897031202" border="0" alt="" src="http://2.bp.blogspot.com/_7WfR_akYPWo/S9ox-ddYaCI/AAAAAAAAAK0/IqdrXAdXu-4/s400/DSC01430.JPG" /></a>


Here's the checkball to burp.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465735436589368594" border="0" alt="" src="http://4.bp.blogspot.com/_7WfR_akYPWo/S9oxa74shRI/AAAAAAAAAKc/AtN57ksG7O0/s400/DSC01431.JPG" /></a>

Now clean them with WD-40.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465736027870043010" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S9ox9Wk_m4I/AAAAAAAAAKk/r92MWi9iSu4/s400/DSC01428.JPG" /></a>
Burp and pump up, a couple of times to flush out the junk.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465735425740481266" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S9oxaTeHovI/AAAAAAAAAKU/sn6V17NIOxg/s400/DSC01432.JPG" /></a>

Now that they're clean, we will fill them with fresh oil. Squeeze the adjuster and open the ball. Don't release it yet.

<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465735420609775698" border="0" alt="" src="http://4.bp.blogspot.com/_7WfR_akYPWo/S9oxaAW3SFI/AAAAAAAAAKM/HCcu4AvVIJE/s400/DSC01437.JPG" /></a>

Now release submerged in new oil. Purge, clean, and refill all eight of them.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465735412300655506" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S9oxZhZ0K5I/AAAAAAAAAKE/tEZ5mdVBias/s400/DSC01436.JPG" /></a>
Now check the tiny hole in the rockers. Make sure they all are clean.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465735406338500786" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S9oxZLMU6LI/AAAAAAAAAJ8/7r4RhzSr4N4/s400/DSC01441.JPG" /></a>

Here we are washing again.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465734382524489106" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S9owdlMC3ZI/AAAAAAAAAJ0/0NKpUh0xRoc/s400/DSC01442.JPG" /></a>

Blow dry.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465734369292961410" border="0" alt="" src="http://1.bp.blogspot.com/_7WfR_akYPWo/S9owcz5ZxoI/AAAAAAAAAJs/LfbsZmjlC4I/s400/DSC01446.JPG" /></a>

Oil the steel parts so they don't rust. A periodic correct oil can is the only way to do this.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465734361329344098" border="0" alt="" src="http://4.bp.blogspot.com/_7WfR_akYPWo/S9owcWOunmI/AAAAAAAAAJk/uKRxblxEHiU/s400/DSC01447.JPG" /></a>

Okay enough with the heads for now. What's with the ATF?

<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465734358194617746" border="0" alt="" src="http://3.bp.blogspot.com/_7WfR_akYPWo/S9owcKjWfZI/AAAAAAAAAJc/BvNbuVai8Vw/s400/DSC01448.JPG" /></a>

I was told by Hotsauce via The Judge that you can marinate the gaskets in ATF and they will stay where you put them during assembly and if you have to take things apart the gaskets won't stick and you can re-use them. Looks like a horror movie though.
<a href="http://tearitupfixitrepeat.blogspot.com/2010/04/lash-adjusters.html"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5465734348461926418" border="0" alt="" src="http://4.bp.blogspot.com/_7WfR_akYPWo/S9owbmS5aBI/AAAAAAAAAJU/p0y0vg-rYOo/s400/DSC01449.JPG" /></a>

We should be going up with this motor tomorrow!

KrOwN
04-29-2010, 9:29 PM
awsome write up mr williams!!! good trick w/ the ATF also!

CHEN
04-30-2010, 8:22 AM
this thread is so good....so much good info.

JPWilliams
05-01-2010, 8:29 PM
Let's get this motor back together. Panhead Pat came over to help.

We have to replace the pistons with the oversized pistons.

Take out both wristpin snap rings and throw then away.

http://1.bp.blogspot.com/_7WfR_akYPWo/S9wsrjUQyVI/AAAAAAAAAPU/nE6zDReOcZk/s400/DSC01454.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wsrjUQyVI/AAAAAAAAAPU/nE6zDReOcZk/s1600/DSC01454.JPG)
http://2.bp.blogspot.com/_7WfR_akYPWo/S9wsrd_mVyI/AAAAAAAAAPM/pe4xDFw_AD4/s400/DSC01453.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9wsrd_mVyI/AAAAAAAAAPM/pe4xDFw_AD4/s1600/DSC01453.JPG)


Gently tap out the wristpins. The screwdriver's handle made a nice soft drift.
http://4.bp.blogspot.com/_7WfR_akYPWo/S9wsq5gqwBI/AAAAAAAAAPE/NUXlmRHSeOk/s400/DSC01455.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9wsq5gqwBI/AAAAAAAAAPE/NUXlmRHSeOk/s1600/DSC01455.JPG)


Out it comes.
http://4.bp.blogspot.com/_7WfR_akYPWo/S9wsqZpoI0I/AAAAAAAAAO8/v7BMCFvTiVA/s400/DSC01456.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9wsqZpoI0I/AAAAAAAAAO8/v7BMCFvTiVA/s1600/DSC01456.JPG)


Old piston is gone.
http://2.bp.blogspot.com/_7WfR_akYPWo/S9wsqKS3_cI/AAAAAAAAAO0/FKeGnAh4_UI/s400/DSC01457.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9wsqKS3_cI/AAAAAAAAAO0/FKeGnAh4_UI/s1600/DSC01457.JPG)


Repeat the steps for the other piston.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wr0__HrjI/AAAAAAAAAOs/uGloCjW7gK0/s400/DSC01458.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wr0__HrjI/AAAAAAAAAOs/uGloCjW7gK0/s1600/DSC01458.JPG)



Remember I said throw away the snap rings? I forgot to order those with the rest of parts and I had to scramble to find some locally or wait another week to build. I had to drive 60 miles one way to these. I needed 4, they had 6. I bought them all just in case.

http://1.bp.blogspot.com/_7WfR_akYPWo/S9wr0PXmsWI/AAAAAAAAAOk/aN1jvh1ZOB4/s400/DSC01459.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wr0PXmsWI/AAAAAAAAAOk/aN1jvh1ZOB4/s1600/DSC01459.JPG)


The pistons have a directional arrow so you want to the first one snap ring into the groove the will be on the camchain side of the cylinder. This will make second snap ring easier to install without working around the extra studs in the case.
http://2.bp.blogspot.com/_7WfR_akYPWo/S9wrzlddFpI/AAAAAAAAAOc/cgfgvGULT7M/s400/DSC01461.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9wrzlddFpI/AAAAAAAAAOc/cgfgvGULT7M/s1600/DSC01461.JPG)


Slide the ring so that the gap in the ring is opposite the gap in the piston.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wrzNbKUvI/AAAAAAAAAOU/aAj2empEhxU/s400/DSC01468.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wrzNbKUvI/AAAAAAAAAOU/aAj2empEhxU/s1600/DSC01468.JPG)


Oil the piston where the wristpin rides.
http://3.bp.blogspot.com/_7WfR_akYPWo/S9wry6GJ5cI/AAAAAAAAAOM/A88CzVx2zvI/s400/DSC01469.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9wry6GJ5cI/AAAAAAAAAOM/A88CzVx2zvI/s1600/DSC01469.JPG)


Oil the wristpin and the connecting rod hole.
http://4.bp.blogspot.com/_7WfR_akYPWo/S9wrAZBU3kI/AAAAAAAAAOE/k6cu9k8dC_E/s400/DSC01470.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9wrAZBU3kI/AAAAAAAAAOE/k6cu9k8dC_E/s1600/DSC01470.JPG)


Line everything up and put the wristpin through the piston and connecting rod.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wq_ckBpPI/AAAAAAAAAN8/tSi2_OzsbVs/s400/DSC01471.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wq_ckBpPI/AAAAAAAAAN8/tSi2_OzsbVs/s1600/DSC01471.JPG)


Install the other snap ring.
http://2.bp.blogspot.com/_7WfR_akYPWo/S9wq-52cWpI/AAAAAAAAAN0/F5tlhmvTjuQ/s400/DSC01473.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9wq-52cWpI/AAAAAAAAAN0/F5tlhmvTjuQ/s1600/DSC01473.JPG)


Again move the gap of the ring opposite the gap in the piston.
http://2.bp.blogspot.com/_7WfR_akYPWo/S9wq-VAuOgI/AAAAAAAAANs/y13ncuXGGhc/s400/DSC01478.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9wq-VAuOgI/AAAAAAAAANs/y13ncuXGGhc/s1600/DSC01478.JPG)


Yea! Piston is on.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wq-G86alI/AAAAAAAAANk/y9WzCVNJ3w8/s400/DSC01479.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wq-G86alI/AAAAAAAAANk/y9WzCVNJ3w8/s1600/DSC01479.JPG)


Get ready to do the piston rings. READ THE BOOK! It is easy to put the piston rings in upside down, backwards, gaps misaligned or otherwise wrong.
http://2.bp.blogspot.com/_7WfR_akYPWo/S9wqG7dsolI/AAAAAAAAANc/gOuEs7L3bj8/s400/DSC01480.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9wqG7dsolI/AAAAAAAAANc/gOuEs7L3bj8/s1600/DSC01480.JPG)


Work the rings into the grooves.
http://3.bp.blogspot.com/_7WfR_akYPWo/S9wqGVlT2AI/AAAAAAAAANU/8TT-l7pxCxk/s400/DSC01481.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9wqGVlT2AI/AAAAAAAAANU/8TT-l7pxCxk/s1600/DSC01481.JPG)


Ringed and ready.
http://3.bp.blogspot.com/_7WfR_akYPWo/S9wqF79p0hI/AAAAAAAAANM/9du1RgiE3Gk/s400/DSC01482.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9wqF79p0hI/AAAAAAAAANM/9du1RgiE3Gk/s1600/DSC01482.JPG)


Oil the rings and the pistons.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wqFo3Q78I/AAAAAAAAANE/f8uQFPGSB50/s400/DSC01483.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wqFo3Q78I/AAAAAAAAANE/f8uQFPGSB50/s1600/DSC01483.JPG)


Old Easyrider trick, use a hose clamp as ring compressor. This is $2.95 dryer vent clamp with quick disconnect from ACE Hardware.
http://3.bp.blogspot.com/_7WfR_akYPWo/S9wpB5Q16iI/AAAAAAAAAM8/2yfIDPqFbCI/s400/DSC01485.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9wpB5Q16iI/AAAAAAAAAM8/2yfIDPqFbCI/s1600/DSC01485.JPG)
http://4.bp.blogspot.com/_7WfR_akYPWo/S9wpBalceyI/AAAAAAAAAM0/duKYQY913L8/s400/DSC01486.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9wpBalceyI/AAAAAAAAAM0/duKYQY913L8/s1600/DSC01486.JPG)


Oil the cylinder wall.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wpA0cTPgI/AAAAAAAAAMs/uuVxGu-zMN8/s400/DSC01487.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wpA0cTPgI/AAAAAAAAAMs/uuVxGu-zMN8/s1600/DSC01487.JPG)


Slide it on.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wpAnd4xrI/AAAAAAAAAMk/mLukBsWpjXg/s400/DSC01490.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wpAnd4xrI/AAAAAAAAAMk/mLukBsWpjXg/s1600/DSC01490.JPG)



Take the hose clamp off, when the rings are inside the cylinder.
http://4.bp.blogspot.com/_7WfR_akYPWo/S9wpAPB1MXI/AAAAAAAAAMc/3N3lfAJs3cw/s400/DSC01491.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9wpAPB1MXI/AAAAAAAAAMc/3N3lfAJs3cw/s1600/DSC01491.JPG)


Looking good.
http://3.bp.blogspot.com/_7WfR_akYPWo/S9wn1XY_iwI/AAAAAAAAAMU/hVgOTjxDY2Y/s400/DSC01492.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9wn1XY_iwI/AAAAAAAAAMU/hVgOTjxDY2Y/s1600/DSC01492.JPG)



I looked up the torque value on these two nuts. 18 ft*lb. I then realised I could fit a torque wrench on it. I used my calibrated elbow instead. (Add torque adaptors to my Christmas list.)

http://3.bp.blogspot.com/_7WfR_akYPWo/S9wn0-sttfI/AAAAAAAAAMM/7L9j7NPr6zo/s400/DSC01496.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9wn0-sttfI/AAAAAAAAAMM/7L9j7NPr6zo/s1600/DSC01496.JPG)


The next picture should both cylinders on with pistons in them, but we fought the rear oil rings for 2 hours maybe. The wavy oil ring would not go in. It acted like it was too big or something. Here it is laughing at us.

http://1.bp.blogspot.com/_7WfR_akYPWo/S9wn0FG-1tI/AAAAAAAAAME/Zd4HsUJ_E74/s400/DSC01497.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wn0FG-1tI/AAAAAAAAAME/Zd4HsUJ_E74/s1600/DSC01497.JPG)


Plan B. Put the piston into the cylinder on the bench then attach the piston to the connecting rod. Take out one snap ring and the wristpen. We used a 14mm socket and extension as drift this time to clear the installed snap ring.
http://2.bp.blogspot.com/_7WfR_akYPWo/S9wnzittWfI/AAAAAAAAAL8/iusbzlqjAhw/s400/DSC01498.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9wnzittWfI/AAAAAAAAAL8/iusbzlqjAhw/s1600/DSC01498.JPG)


Work the piston and rings into the cylinder on the bench with the wristpin hanging out.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wnzKy6ObI/AAAAAAAAAL0/J-DwHy2S8pU/s400/DSC01499.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wnzKy6ObI/AAAAAAAAAL0/J-DwHy2S8pU/s1600/DSC01499.JPG)
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wlbf-5SoI/AAAAAAAAALU/tdKqpDWe1vU/s400/DSC01502.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wlbf-5SoI/AAAAAAAAALU/tdKqpDWe1vU/s1600/DSC01502.JPG)

Now put the cylinder, piston, rings, and wristpen onto connecting rod.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wla-abo_I/AAAAAAAAALM/i8fj2F7brRs/s400/DSC01503.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wla-abo_I/AAAAAAAAALM/i8fj2F7brRs/s1600/DSC01503.JPG)

Tap the wristpen through and put the other snapring in.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9wlaTGtVFI/AAAAAAAAALE/_QfZ92J8iPw/s400/DSC01504.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9wlaTGtVFI/AAAAAAAAALE/_QfZ92J8iPw/s1600/DSC01504.JPG)

Now we're done for the night.
http://3.bp.blogspot.com/_7WfR_akYPWo/S9wl7xQRIGI/AAAAAAAAALk/JKdAcmC3114/s400/DSC01505.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9wl7xQRIGI/AAAAAAAAALk/JKdAcmC3114/s1600/DSC01505.JPG)

JPWilliams
05-02-2010, 8:52 AM
I got extra help today. Hotsauce and Pathead Pat helped out today. I'm still not sure the help was worth the abuse though.

Getting to it. New camchains.
http://4.bp.blogspot.com/_7WfR_akYPWo/S917hpBKTKI/AAAAAAAAAUU/6ObiRr38HBk/s400/DSC01508.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S917hpBKTKI/AAAAAAAAAUU/6ObiRr38HBk/s1600/DSC01508.JPG)

Start fishing.

http://2.bp.blogspot.com/_7WfR_akYPWo/S917hIEu25I/AAAAAAAAAUM/nrEaJmpuzI4/s400/DSC01509.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S917hIEu25I/AAAAAAAAAUM/nrEaJmpuzI4/s1600/DSC01509.JPG)

Through the cylinder.
http://1.bp.blogspot.com/_7WfR_akYPWo/S917ghJrokI/AAAAAAAAAUE/oszMIGrdI4w/s400/DSC01511.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S917ghJrokI/AAAAAAAAAUE/oszMIGrdI4w/s1600/DSC01511.JPG)

Put the guide back on.

http://3.bp.blogspot.com/_7WfR_akYPWo/S917gLSfPQI/AAAAAAAAAT8/UIDA2fV2pqA/s400/DSC01512.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S917gLSfPQI/AAAAAAAAAT8/UIDA2fV2pqA/s1600/DSC01512.JPG)


Now the rear one.
http://2.bp.blogspot.com/_7WfR_akYPWo/S917f0izjtI/AAAAAAAAAT0/zIDY37_5pRw/s400/DSC01517.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S917f0izjtI/AAAAAAAAAT0/zIDY37_5pRw/s1600/DSC01517.JPG)

This gear can go on.

http://2.bp.blogspot.com/_7WfR_akYPWo/S916p-x3V9I/AAAAAAAAATs/IN2Svh2p9hw/s400/DSC01516.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S916p-x3V9I/AAAAAAAAATs/IN2Svh2p9hw/s1600/DSC01516.JPG)

Headgasket on.
http://4.bp.blogspot.com/_7WfR_akYPWo/S916pBEUkyI/AAAAAAAAATk/4K1aFuUPjaA/s400/DSC01519.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S916pBEUkyI/AAAAAAAAATk/4K1aFuUPjaA/s1600/DSC01519.JPG)

Put the head on and fish the chain.

http://2.bp.blogspot.com/_7WfR_akYPWo/S916oYPxGGI/AAAAAAAAATU/JnO4B1v8wC4/s400/DSC01521.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S916oYPxGGI/AAAAAAAAATU/JnO4B1v8wC4/s1600/DSC01521.JPG)
OOOOPs! I forgot to put the studs back in the bottom side of the used heads. Off it comes.

These two.

http://4.bp.blogspot.com/_7WfR_akYPWo/S916n6xZI7I/AAAAAAAAATM/uEK1Cbf0sNM/s400/DSC01522.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S916n6xZI7I/AAAAAAAAATM/uEK1Cbf0sNM/s1600/DSC01522.JPG)

Set 'em! Don't forget 'em.

http://3.bp.blogspot.com/_7WfR_akYPWo/S9148pRtHaI/AAAAAAAAATE/9idCztCjbko/s400/DSC01524.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9148pRtHaI/AAAAAAAAATE/9idCztCjbko/s1600/DSC01524.JPG)

Let's do the EPA block off plates while they're on the bench, too.

http://2.bp.blogspot.com/_7WfR_akYPWo/S9148INmTpI/AAAAAAAAAS8/rOHiALjadms/s400/DSC01525.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9148INmTpI/AAAAAAAAAS8/rOHiALjadms/s1600/DSC01525.JPG)

http://1.bp.blogspot.com/_7WfR_akYPWo/S9147o9PucI/AAAAAAAAAS0/27Za80ZiD7M/s400/DSC01526.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9147o9PucI/AAAAAAAAAS0/27Za80ZiD7M/s1600/DSC01526.JPG)



Now back to where we started.

http://3.bp.blogspot.com/_7WfR_akYPWo/S9147LZXrOI/AAAAAAAAASs/4ZnwVgeEpF0/s400/DSC01527.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9147LZXrOI/AAAAAAAAASs/4ZnwVgeEpF0/s1600/DSC01527.JPG)



Chain over the cam gear.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9146h63dyI/AAAAAAAAASk/1Wzl08nF6LA/s400/DSC01529.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9146h63dyI/AAAAAAAAASk/1Wzl08nF6LA/s1600/DSC01529.JPG)

Okay time to time the chain to the crank. The books were a little goofy. The picture showed the lines on the gear even with head where you could read "F", but the book stated lopes up. The book pictures of the rotor marks and the case marks didn't match the book either. The lettered marks were where you could see them with the sidecover on. After playing with the crank. We found lopes down and the proper rotor marks for the case mark.
http://2.bp.blogspot.com/_7WfR_akYPWo/S9zu_Rb2TMI/AAAAAAAAASE/4wVMAxcMMqk/s400/DSC01532.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9zu_Rb2TMI/AAAAAAAAASE/4wVMAxcMMqk/s1600/DSC01532.JPG)

Lube the journals.

http://3.bp.blogspot.com/_7WfR_akYPWo/S9zu-xq9ajI/AAAAAAAAAR8/PcOKvFacY8M/s400/DSC01533.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9zu-xq9ajI/AAAAAAAAAR8/PcOKvFacY8M/s1600/DSC01533.JPG)



Put the adjusters into the rockers.
http://4.bp.blogspot.com/_7WfR_akYPWo/S9ztpMvFcNI/AAAAAAAAAR0/GLgi_RjlXg4/s400/DSC01534.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9ztpMvFcNI/AAAAAAAAAR0/GLgi_RjlXg4/s1600/DSC01534.JPG)

http://3.bp.blogspot.com/_7WfR_akYPWo/S9ztoSyrIaI/AAAAAAAAARs/tOoQZzXmMm0/s400/DSC01535.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9ztoSyrIaI/AAAAAAAAARs/tOoQZzXmMm0/s1600/DSC01535.JPG)

There is no gasket between rocker box and head because they are matchined as set. Guy Mobley at http://www.shermscycleproducts.com/ recommended permatex 29132 (http://www.permatex.com/products/Automotive/automotive_gasketing/specialty_gasket_maker/MotoSeal_1_Ultimate_Gasket_Maker_Grey.htm) to seal the rocker box top and the cam plug.

http://3.bp.blogspot.com/_7WfR_akYPWo/S9ztoNVAi-I/AAAAAAAAARk/d7UrZCvkK80/s400/DSC01536.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9ztoNVAi-I/AAAAAAAAARk/d7UrZCvkK80/s1600/DSC01536.JPG)

Smear it on with a thin coat and let it get tacky.

http://4.bp.blogspot.com/_7WfR_akYPWo/S9ztnkD_m3I/AAAAAAAAARc/Y_52jObz2-Q/s400/DSC01540.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9ztnkD_m3I/AAAAAAAAARc/Y_52jObz2-Q/s1600/DSC01540.JPG)

http://3.bp.blogspot.com/_7WfR_akYPWo/S9ztnaefguI/AAAAAAAAARU/DrH0U54Op-M/s400/DSC01542.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9ztnaefguI/AAAAAAAAARU/DrH0U54Op-M/s1600/DSC01542.JPG)

Put it together.

http://3.bp.blogspot.com/_7WfR_akYPWo/S9ztK-lZpFI/AAAAAAAAARE/_oOGOoTNVtI/s400/DSC01544.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S9ztK-lZpFI/AAAAAAAAARE/_oOGOoTNVtI/s1600/DSC01544.JPG)


Torque time, follow the book sequence.
http://1.bp.blogspot.com/_7WfR_akYPWo/S9ztJ5OXQjI/AAAAAAAAAQ0/WqtUt1TOM1I/s400/DSC01551.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9ztJ5OXQjI/AAAAAAAAAQ0/WqtUt1TOM1I/s1600/DSC01551.JPG)

Looking good.

http://2.bp.blogspot.com/_7WfR_akYPWo/S9ztJfCi9OI/AAAAAAAAAQs/6D7aHMz-pec/s400/DSC01553.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9ztJfCi9OI/AAAAAAAAAQs/6D7aHMz-pec/s1600/DSC01553.JPG)

Ready for the top. I used the permatex to glue the rubbers in the cover.

http://2.bp.blogspot.com/_7WfR_akYPWo/S9zp6jRNmxI/AAAAAAAAAQk/j5_OnJikIiQ/s400/DSC01558.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9zp6jRNmxI/AAAAAAAAAQk/j5_OnJikIiQ/s1600/DSC01558.JPG)

Line it up, so you don't mess up the gasket.

http://4.bp.blogspot.com/_7WfR_akYPWo/S9zp6PWJ_SI/AAAAAAAAAQc/0PUFBc0zrXk/s400/DSC01559.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9zp6PWJ_SI/AAAAAAAAAQc/0PUFBc0zrXk/s1600/DSC01559.JPG)

There is a torque wrench attached to this speed handle.

http://2.bp.blogspot.com/_7WfR_akYPWo/S9zp5kw9T5I/AAAAAAAAAQU/3i6je9t1YM4/s400/DSC01560.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9zp5kw9T5I/AAAAAAAAAQU/3i6je9t1YM4/s1600/DSC01560.JPG)

Forget to put the oil line on 'til now. Still doable, but would have been easier before the top went on.

http://2.bp.blogspot.com/_7WfR_akYPWo/S9zp5X8yMCI/AAAAAAAAAQM/lwmbk75wQCo/s400/DSC01563.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9zp5X8yMCI/AAAAAAAAAQM/lwmbk75wQCo/s1600/DSC01563.JPG)

Put the spark plug tube back in.

http://4.bp.blogspot.com/_7WfR_akYPWo/S9zp43Fu7fI/AAAAAAAAAQE/mYY9druwts4/s400/DSC01564.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9zp43Fu7fI/AAAAAAAAAQE/mYY9druwts4/s1600/DSC01564.JPG)

Okay this is when you time when roll the crank 305 degrees and put the rear cam in and you're done with the top end, but of course it couldn't be that simple. We rolled it and when just about got to the mark the front chain made some funny popping noises. "Did it jump some teeth?" "Don't know, tear it apart and redo it to be sure."


Let's put the camchain tensioner in after we time it this time. That's the wart halfway down the front cylinder.

http://4.bp.blogspot.com/_7WfR_akYPWo/S9zpTXAwDjI/AAAAAAAAAP8/NghsW1jGQrc/s400/DSC01565.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9zpTXAwDjI/AAAAAAAAAP8/NghsW1jGQrc/s1600/DSC01565.JPG)


Sorry, picture quality and quantity go downhill late in the day, especially after a major re-do. Here's the motor with the cams in and the rocker boxes on.
http://4.bp.blogspot.com/_7WfR_akYPWo/S9zpSwYifjI/AAAAAAAAAP0/843PHTqCz_0/s400/DSC01566.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9zpSwYifjI/AAAAAAAAAP0/843PHTqCz_0/s1600/DSC01566.JPG)

Rear tensioner going in.

http://1.bp.blogspot.com/_7WfR_akYPWo/S9zpSR15JZI/AAAAAAAAAPs/bi3BKeYjQNQ/s400/DSC01567.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S9zpSR15JZI/AAAAAAAAAPs/bi3BKeYjQNQ/s1600/DSC01567.JPG)

Both covers on.

http://4.bp.blogspot.com/_7WfR_akYPWo/S9zpSHBlUYI/AAAAAAAAAPk/B1yNF9SvRtg/s400/DSC01569.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S9zpSHBlUYI/AAAAAAAAAPk/B1yNF9SvRtg/s1600/DSC01569.JPG)

Looks like a motor. Time for a beer.

http://2.bp.blogspot.com/_7WfR_akYPWo/S9zpRQEqpKI/AAAAAAAAAPc/xz2ojOg8CRg/s400/DSC01571.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S9zpRQEqpKI/AAAAAAAAAPc/xz2ojOg8CRg/s1600/DSC01571.JPG)

JPWilliams
05-02-2010, 11:43 AM
I forgot to mention that compression releases didn't go back in.

JPWilliams
05-02-2010, 2:46 PM
Cuss and swear!!! I left the compression release out on purpose, but I forgot to put the camchain extensioner shoes back in.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273154522_1010435000_30649738_5286095_n. jpg

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs197.snc3/20431_1259273194523_1010435000_30649739_1327835_n. jpg

JPWilliams
05-02-2010, 4:56 PM
Bad news here. ugh.

http://tearitupfixitrepeat.blogspot.com/2010/05/cuss-and-swear.html

xpunkindrublicx13
05-11-2010, 7:11 PM
I hate when I forget stuff. It always happens when things are going together really easily. Looks great though.

JPWilliams
05-16-2010, 4:34 PM
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9YJa5MsRI/AAAAAAAAAd8/015p8v4KfBw/s400/DSC01595.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9YJa5MsRI/AAAAAAAAAd8/015p8v4KfBw/s1600/DSC01595.JPG)
Fresh headgaskets. Now we can get to work.

http://4.bp.blogspot.com/_7WfR_akYPWo/S-9YI0PDfNI/AAAAAAAAAd0/rvNgWYPa5ZM/s400/DSC01599.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9YI0PDfNI/AAAAAAAAAd0/rvNgWYPa5ZM/s1600/DSC01599.JPG)
The boys came out to the garage to help, too.


Again make sure there is plastic part hanging of the jug BEFORE (http://tearitupfixitrepeat.blogspot.com/2010/05/cuss-and-swear.html) you put the heads on.
http://2.bp.blogspot.com/_7WfR_akYPWo/S-9YIQRzItI/AAAAAAAAAds/aB2R4kfdAaM/s400/DSC01601.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9YIQRzItI/AAAAAAAAAds/aB2R4kfdAaM/s1600/DSC01601.JPG)
http://4.bp.blogspot.com/_7WfR_akYPWo/S-9YHzh3jHI/AAAAAAAAAdk/I8R24B3GrX4/s400/DSC01602.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9YHzh3jHI/AAAAAAAAAdk/I8R24B3GrX4/s1600/DSC01602.JPG)


Fast foward. (If you need to see this part, click here (http://tearitupfixitrepeat.blogspot.com/2010/05/heads-and-timing.html))
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9YHcBY1cI/AAAAAAAAAdc/iyqBi3jwbDk/s400/DSC01603.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9YHcBY1cI/AAAAAAAAAdc/iyqBi3jwbDk/s1600/DSC01603.JPG)
Heads are on again.



http://4.bp.blogspot.com/_7WfR_akYPWo/S-9XLQ6B4TI/AAAAAAAAAdM/i-giaRz4zy4/s400/DSC01607.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9XLQ6B4TI/AAAAAAAAAdM/i-giaRz4zy4/s1600/DSC01607.JPG)
Replaced the water line o-ring on both heads.

http://4.bp.blogspot.com/_7WfR_akYPWo/S-9XcmTAoTI/AAAAAAAAAdU/PkUg4Ch9hqI/s400/DSC01605.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9XcmTAoTI/AAAAAAAAAdU/PkUg4Ch9hqI/s1600/DSC01605.JPG)
Ready to go up with clutch side.

http://3.bp.blogspot.com/_7WfR_akYPWo/S-9XLBeVjlI/AAAAAAAAAdE/cYLPzgHTjms/s400/DSC01608.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9XLBeVjlI/AAAAAAAAAdE/cYLPzgHTjms/s1600/DSC01608.JPG)
Water pump gears and chain, etc.

http://3.bp.blogspot.com/_7WfR_akYPWo/S-9XKZT83bI/AAAAAAAAAc0/Snb7sFv8FEA/s400/DSC01610.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9XKZT83bI/AAAAAAAAAc0/Snb7sFv8FEA/s1600/DSC01610.JPG)
This shaft has two pins and two snap rings to hold it in place.


http://1.bp.blogspot.com/_7WfR_akYPWo/S-9XJ_sI9CI/AAAAAAAAAcs/3Q-G--xSnbo/s400/DSC01611.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9XJ_sI9CI/AAAAAAAAAcs/3Q-G--xSnbo/s1600/DSC01611.JPG)
Put the shaft into the bearing the case and the pin the slot of the gear. Don't put the other gear on crankshaft yet. (Like I did in this pic.) Also roll the gear so that the pin is horizontal so if won't fall out.

JPWilliams
05-16-2010, 4:35 PM
http://2.bp.blogspot.com/_7WfR_akYPWo/S-9WmnFaw3I/AAAAAAAAAck/JsMyeL8dQR4/s400/DSC01612.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9WmnFaw3I/AAAAAAAAAck/JsMyeL8dQR4/s1600/DSC01612.JPG)
The primary gear goes tall shoulder toward the inside, before the waterpump gears.

http://4.bp.blogspot.com/_7WfR_akYPWo/S-9WmDyOJhI/AAAAAAAAAcc/XqQEp9bRFOM/s400/DSC01613.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9WmDyOJhI/AAAAAAAAAcc/XqQEp9bRFOM/s1600/DSC01613.JPG)
Both of the waterpump gears and chain slide on together.
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9Wlko_oJI/AAAAAAAAAcU/zd5JlvUC6M4/s400/DSC01614.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9Wlko_oJI/AAAAAAAAAcU/zd5JlvUC6M4/s1600/DSC01614.JPG)
Note: No dowel in the above picture and two below. I robbed one from the side cover. I don't know what happened to it, but I blame the last guy that rebuilt it.
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9WBYKAV9I/AAAAAAAAAcM/VNL-2efaLmQ/s400/DSC01615.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9WBYKAV9I/AAAAAAAAAcM/VNL-2efaLmQ/s1600/DSC01615.JPG)
Ready to go. I had to rob a dowel pin from the left cover because one of the waterpump chain tension dowels was missing, I'm blaming the guy who rebuilt it.

http://3.bp.blogspot.com/_7WfR_akYPWo/S-9WA94axqI/AAAAAAAAAcE/Z3LIO3Zn75A/s400/DSC01616.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9WA94axqI/AAAAAAAAAcE/Z3LIO3Zn75A/s1600/DSC01616.JPG)

http://1.bp.blogspot.com/_7WfR_akYPWo/S-9WAZWOAfI/AAAAAAAAAb8/ISvXYl32Qi4/s400/DSC01617.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9WAZWOAfI/AAAAAAAAAb8/ISvXYl32Qi4/s1600/DSC01617.JPG)
The tensioner is on. The spring is kind of wierd because it's not really captured, just hooked on the threads of a bolt. The starter gear slides back onto its place with the one way clutch.

http://2.bp.blogspot.com/_7WfR_akYPWo/S-9WAL80kuI/AAAAAAAAAb0/eBY6IMmRkNI/s400/DSC01618.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9WAL80kuI/AAAAAAAAAb0/eBY6IMmRkNI/s1600/DSC01618.JPG)
Clutch basket on the splines.

http://3.bp.blogspot.com/_7WfR_akYPWo/S-9V_hGzEOI/AAAAAAAAAbs/LuglW6MzQcs/s400/DSC01619.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9V_hGzEOI/AAAAAAAAAbs/LuglW6MzQcs/s1600/DSC01619.JPG)
Washer on the shaft.

http://1.bp.blogspot.com/_7WfR_akYPWo/S-9VrjGRk9I/AAAAAAAAAbk/TijhAahLE6Q/s400/DSC01623.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9VrjGRk9I/AAAAAAAAAbk/TijhAahLE6Q/s1600/DSC01623.JPG)
Inside of the clutch basket goes on.


Stack the clutch.
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9VrFVxhbI/AAAAAAAAAbc/_OHJMHAZAjg/s400/DSC01624.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9VrFVxhbI/AAAAAAAAAbc/_OHJMHAZAjg/s1600/DSC01624.JPG)
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9VquT_rXI/AAAAAAAAAbU/28wHtLZjXYU/s400/DSC01625.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9VquT_rXI/AAAAAAAAAbU/28wHtLZjXYU/s1600/DSC01625.JPG)
Steels and frictions, steel and frictions.

http://3.bp.blogspot.com/_7WfR_akYPWo/S-9VqWDwCMI/AAAAAAAAAbM/-nMWINjDIwo/s400/DSC01626.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9VqWDwCMI/AAAAAAAAAbM/-nMWINjDIwo/s1600/DSC01626.JPG)
The last friction plate is offset into the stand off.


The clutch spring stack up. I am using a meanstreak clutch spring and Judge's clutch washers.
Click here (http://www.gadgetjq.com/clutch_spring_replacement.htm#Judgesgear) for details.

http://1.bp.blogspot.com/_7WfR_akYPWo/S-9VpxwE5tI/AAAAAAAAAbE/MU0Wvp-hX6c/s400/DSC01629.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9VpxwE5tI/AAAAAAAAAbE/MU0Wvp-hX6c/s1600/DSC01629.JPG)
http://4.bp.blogspot.com/_7WfR_akYPWo/S-9VH1sPQHI/AAAAAAAAAa8/-YlL7hdr774/s400/DSC01630.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9VH1sPQHI/AAAAAAAAAa8/-YlL7hdr774/s1600/DSC01630.JPG)

http://1.bp.blogspot.com/_7WfR_akYPWo/S-9VHqSBfaI/AAAAAAAAAa0/y0YIPfSjGl4/s400/DSC01631.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9VHqSBfaI/AAAAAAAAAa0/y0YIPfSjGl4/s1600/DSC01631.JPG)
The end of the basket goes on.

http://1.bp.blogspot.com/_7WfR_akYPWo/S-9VHOkbvQI/AAAAAAAAAas/Gd6wT_lcddg/s400/DSC01632.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9VHOkbvQI/AAAAAAAAAas/Gd6wT_lcddg/s1600/DSC01632.JPG)
The spring stack goes on.

http://4.bp.blogspot.com/_7WfR_akYPWo/S-9VGobIW8I/AAAAAAAAAak/TbbCjCkZ0ps/s400/DSC01633.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9VGobIW8I/AAAAAAAAAak/TbbCjCkZ0ps/s1600/DSC01633.JPG)
The nut goes on.

http://3.bp.blogspot.com/_7WfR_akYPWo/S-9VGDnpdTI/AAAAAAAAAac/NRAkuBtcILE/s400/DSC01634.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9VGDnpdTI/AAAAAAAAAac/NRAkuBtcILE/s1600/DSC01634.JPG)
The penny locks the motor gears.

JPWilliams
05-16-2010, 4:36 PM
http://4.bp.blogspot.com/_7WfR_akYPWo/S-9UtQh9PYI/AAAAAAAAAaU/Wqny-1NeOeg/s400/DSC01635.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9UtQh9PYI/AAAAAAAAAaU/Wqny-1NeOeg/s1600/DSC01635.JPG)
Torque the clutch hub nut to 110 ft*lb.

http://2.bp.blogspot.com/_7WfR_akYPWo/S-9Usyk9o8I/AAAAAAAAAaM/hlXD-htyqcs/s400/DSC01636.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9Usyk9o8I/AAAAAAAAAaM/hlXD-htyqcs/s1600/DSC01636.JPG)
Switch the penny position and torque the primary nut to 110 ft*lb.


http://2.bp.blogspot.com/_7WfR_akYPWo/S-9Usv2uhgI/AAAAAAAAAaE/UgNzzxqje08/s400/DSC01637.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9Usv2uhgI/AAAAAAAAAaE/UgNzzxqje08/s1600/DSC01637.JPG)
Clutch rod and throwout bearing go in.

http://1.bp.blogspot.com/_7WfR_akYPWo/S-9UsO4LLMI/AAAAAAAAAZ8/0RiyvIsiE-Q/s400/DSC01638.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9UsO4LLMI/AAAAAAAAAZ8/0RiyvIsiE-Q/s1600/DSC01638.JPG)
The cap and thrust washer go on. I didn't get a shot of the washer in the cap, but it's there.

http://1.bp.blogspot.com/_7WfR_akYPWo/S-9UrmelNoI/AAAAAAAAAZ0/nwZLEKWeYjI/s400/DSC01639.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9UrmelNoI/AAAAAAAAAZ0/nwZLEKWeYjI/s1600/DSC01639.JPG)
The snap ring holds the cap in place. This side is done. I can't put the cover on yet, because I am short a dowel AND I still need to lock the gears with a penny to torque bolts on the other side.


The alternator side was a little tricky. The repair manual says up to 2004, but they do not cover the dual stator set-up that came out like 2000 or so. The early models had the primary gear attached to the rotor and the counter balancer mark was on it. To be transparent, we put this together wrong once and redid it. I am going to show only the right way on this blog entry.

The left side primary gear is seperate for the rotor on the dual stator set-up.
http://1.bp.blogspot.com/_7WfR_akYPWo/S-9QpNPrVGI/AAAAAAAAAZs/sXk7hroJLR8/s400/DSC01640.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9QpNPrVGI/AAAAAAAAAZs/sXk7hroJLR8/s1600/DSC01640.JPG)
It only fits one way.
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9PLbQAzaI/AAAAAAAAAX0/es48eN-3utk/s400/DSC01655.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9PLbQAzaI/AAAAAAAAAX0/es48eN-3utk/s1600/DSC01655.JPG)
You need to turn the motor counter clockwise to align the mark on the primary gear with mark on the counterbalancer gear.
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9PK8BetjI/AAAAAAAAAXs/9iPMuC9Lhuo/s400/DSC01656.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9PK8BetjI/AAAAAAAAAXs/9iPMuC9Lhuo/s1600/DSC01656.JPG)
Like that.


http://2.bp.blogspot.com/_7WfR_akYPWo/S-9QotvyqbI/AAAAAAAAAZk/QIpyZ4D_-JI/s400/DSC01641.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9QotvyqbI/AAAAAAAAAZk/QIpyZ4D_-JI/s1600/DSC01641.JPG)
First stator goes on.
http://2.bp.blogspot.com/_7WfR_akYPWo/S-9QoMIAt1I/AAAAAAAAAZc/RFGx50QFLj0/s400/DSC01642.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9QoMIAt1I/AAAAAAAAAZc/RFGx50QFLj0/s1600/DSC01642.JPG)

Rotor goes on.
http://1.bp.blogspot.com/_7WfR_akYPWo/S-9QnxXA27I/AAAAAAAAAZU/vkMtDnb8-sw/s400/DSC01643.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9QnxXA27I/AAAAAAAAAZU/vkMtDnb8-sw/s1600/DSC01643.JPG)
http://4.bp.blogspot.com/_7WfR_akYPWo/S-9QnqqQhTI/AAAAAAAAAZM/9e0BU3mP-I4/s400/DSC01644.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9QnqqQhTI/AAAAAAAAAZM/9e0BU3mP-I4/s1600/DSC01644.JPG)
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9QMwZSDvI/AAAAAAAAAZE/ONvFN1ayyjc/s400/DSC01645.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9QMwZSDvI/AAAAAAAAAZE/ONvFN1ayyjc/s1600/DSC01645.JPG)
Lock the motor and torque this bolt. I forget the value. I think 58 ft*lb.


This cover is next.
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9QMlMvmiI/AAAAAAAAAY8/rsV1_LT5cqQ/s400/DSC01646.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9QMlMvmiI/AAAAAAAAAY8/rsV1_LT5cqQ/s1600/DSC01646.JPG)

This gasket is easy to confuse up from down and magnet in the rotor wants to grab it.
http://4.bp.blogspot.com/_7WfR_akYPWo/S-9QMKpCc9I/AAAAAAAAAY0/iaTdZZMXVdo/s400/DSC01647.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9QMKpCc9I/AAAAAAAAAY0/iaTdZZMXVdo/s1600/DSC01647.JPG)
http://2.bp.blogspot.com/_7WfR_akYPWo/S-9QLtKy4bI/AAAAAAAAAYs/Kqe_dyfsgvk/s400/DSC01648.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9QLtKy4bI/AAAAAAAAAYs/Kqe_dyfsgvk/s1600/DSC01648.JPG)

This plugs need to go on top of the gasket and Moto-Seal goes on it.
http://2.bp.blogspot.com/_7WfR_akYPWo/S-9QLQYnmSI/AAAAAAAAAYk/Iegd0WEpo4g/s400/DSC01649.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9QLQYnmSI/AAAAAAAAAYk/Iegd0WEpo4g/s1600/DSC01649.JPG)

Slide the cover on and bolt it up.
http://2.bp.blogspot.com/_7WfR_akYPWo/S-9PrGa8boI/AAAAAAAAAYc/k4BO4KbRc8I/s400/DSC01650.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9PrGa8boI/AAAAAAAAAYc/k4BO4KbRc8I/s1600/DSC01650.JPG)
http://2.bp.blogspot.com/_7WfR_akYPWo/S-9Pqlh-iBI/AAAAAAAAAYU/BNJlVn6grsQ/s400/DSC01651.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9Pqlh-iBI/AAAAAAAAAYU/BNJlVn6grsQ/s1600/DSC01651.JPG)
http://1.bp.blogspot.com/_7WfR_akYPWo/S-9PqI4ftkI/AAAAAAAAAYM/FLGzzBMuBXs/s400/DSC01652.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9PqI4ftkI/AAAAAAAAAYM/FLGzzBMuBXs/s1600/DSC01652.JPG)
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9Ppor3VZI/AAAAAAAAAYE/IBkqDHlhRFg/s400/DSC01653.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9Ppor3VZI/AAAAAAAAAYE/IBkqDHlhRFg/s1600/DSC01653.JPG)
Those bolts get torqued to 88 in*lb.

Next comes the shift shaft. Grease the end that goes in the crankcase.
http://2.bp.blogspot.com/_7WfR_akYPWo/S-9PKMqs_8I/AAAAAAAAAXk/iEUMgwwVA-Q/s400/DSC01657.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9PKMqs_8I/AAAAAAAAAXk/iEUMgwwVA-Q/s1600/DSC01657.JPG)
http://1.bp.blogspot.com/_7WfR_akYPWo/S-9PJqqJISI/AAAAAAAAAXc/-Hzn6gSHCAs/s400/DSC01658.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9PJqqJISI/AAAAAAAAAXc/-Hzn6gSHCAs/s1600/DSC01658.JPG)

Put the splines of shift lever over the other shaft and put that bolt in.
http://1.bp.blogspot.com/_7WfR_akYPWo/S-9PJCEbbqI/AAAAAAAAAXU/mxrRlNODOZk/s400/DSC01659.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9PJCEbbqI/AAAAAAAAAXU/mxrRlNODOZk/s1600/DSC01659.JPG)

'nuther gasket
http://4.bp.blogspot.com/_7WfR_akYPWo/S-9OcQR1oMI/AAAAAAAAAXM/Tw9m6gnt6M0/s400/DSC01661.JPG (http://4.bp.blogspot.com/_7WfR_akYPWo/S-9OcQR1oMI/AAAAAAAAAXM/Tw9m6gnt6M0/s1600/DSC01661.JPG)

Grease the shaft of the shift shaft and slide the last cover on.
http://1.bp.blogspot.com/_7WfR_akYPWo/S-9Ob-bgxeI/AAAAAAAAAXE/bBS79fbhLoE/s400/DSC01662.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9Ob-bgxeI/AAAAAAAAAXE/bBS79fbhLoE/s1600/DSC01662.JPG)
http://1.bp.blogspot.com/_7WfR_akYPWo/S-9ObdeaoLI/AAAAAAAAAW8/wh_FPwtI31A/s400/DSC01663.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9ObdeaoLI/AAAAAAAAAW8/wh_FPwtI31A/s1600/DSC01663.JPG)
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9OawyGahI/AAAAAAAAAW0/fyArKUDFZ28/s400/DSC01664.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9OawyGahI/AAAAAAAAAW0/fyArKUDFZ28/s1600/DSC01664.JPG)
http://2.bp.blogspot.com/_7WfR_akYPWo/S-9OamKqkCI/AAAAAAAAAWs/tdeZFxmJs28/s400/DSC01665.JPG (http://2.bp.blogspot.com/_7WfR_akYPWo/S-9OamKqkCI/AAAAAAAAAWs/tdeZFxmJs28/s1600/DSC01665.JPG)

Torque those to 88 in*lb.
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9N5XbEvYI/AAAAAAAAAWU/8MoK14BXBlI/s400/DSC01668.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9N5XbEvYI/AAAAAAAAAWU/8MoK14BXBlI/s1600/DSC01668.JPG)

We'll call that a day.
http://1.bp.blogspot.com/_7WfR_akYPWo/S-9N4seFXmI/AAAAAAAAAWM/IWtb6UYC5Dw/s400/DSC01669.JPG (http://1.bp.blogspot.com/_7WfR_akYPWo/S-9N4seFXmI/AAAAAAAAAWM/IWtb6UYC5Dw/s1600/DSC01669.JPG)

I did have to lay this cover on it just for inspiration I can't put this cover on the motor until it is back in the frame.
http://3.bp.blogspot.com/_7WfR_akYPWo/S-9N4fpkmpI/AAAAAAAAAWE/8NvFswFjwxQ/s400/DSC01670.JPG (http://3.bp.blogspot.com/_7WfR_akYPWo/S-9N4fpkmpI/AAAAAAAAAWE/8NvFswFjwxQ/s1600/DSC01670.JPG)

JPWilliams
05-23-2010, 7:06 AM
Here's the dowel I was missing. Thanks, Guy.

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gRJTTKSTI/AAAAAAAAAlE/J6mjmDciYFA/s400/DSC01689.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


The bolts in the right side are different lengths in different spots. I made this template from the gasket package a gasket a long time ago because I to do clutch springs for people.
http://4.bp.blogspot.com/_7WfR_akYPWo/S_gRI34ORcI/AAAAAAAAAk8/WSc13c5z4z0/s400/DSC01690.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Dang camera battery died. Switching to cell phone camera.

Cover on.

http://3.bp.blogspot.com/_7WfR_akYPWo/S_gRIciX6DI/AAAAAAAAAk0/qX_TnOw4rOU/s400/Photo-0033.jpg (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Bolts torqued to 88 in*lb.

http://4.bp.blogspot.com/_7WfR_akYPWo/S_gQ7wiiefI/AAAAAAAAAks/hQ_z5m85_wc/s400/Photo-0034.jpg (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

The boot holder by the output shaft had a nasty burr. So ...

http://1.bp.blogspot.com/_7WfR_akYPWo/S_gQ7ntIbgI/AAAAAAAAAkk/NlOjqGrInag/s400/Photo-0035.jpg (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)
I filed the raised metal done so it wouldn't give me any problems.

http://4.bp.blogspot.com/_7WfR_akYPWo/S_gQ7HnhHSI/AAAAAAAAAkc/QlOWPcwc4LI/s400/Photo-0036.jpg (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)
Looking good now.

http://3.bp.blogspot.com/_7WfR_akYPWo/S_gQ6kYC_lI/AAAAAAAAAkU/Xyon-Sd1zxU/s400/Photo-0037.jpg (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

New intake o-rings.

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gQ6PEzVQI/AAAAAAAAAkM/p3JsDo9TOnQ/s400/Photo-0038.jpg (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Intake going on .

http://1.bp.blogspot.com/_7WfR_akYPWo/S_gQkirojNI/AAAAAAAAAkE/qaGl85EgvNM/s400/Photo-0039.jpg (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)



Now I just need to get the engine from the cart to the jack to the frame. I'll have to have some help.

http://3.bp.blogspot.com/_7WfR_akYPWo/S_gQkRh7DVI/AAAAAAAAAj8/4RasODmnj1M/s400/Photo-0040.jpg (http://3.bp.blogspot.com/_7WfR_akYPWo/S_gQkRh7DVI/AAAAAAAAAj8/4RasODmnj1M/s1600/Photo-0040.jpg)

Les and Pat came and now we can get to work. My camera is charged now too.


First we spend the rear wheel ...
http://2.bp.blogspot.com/_7WfR_akYPWo/S_gQj-9sexI/AAAAAAAAAj0/bymrXhkfmao/s400/DSC01691.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)
to get the hole in the drive shaft where can see it. More on this later.

http://3.bp.blogspot.com/_7WfR_akYPWo/S_gQjdKzlgI/AAAAAAAAAjs/JecKFfEIRyY/s400/DSC01694.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Grunt!

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gQjI2_wOI/AAAAAAAAAjk/jK9AXjwlRis/s400/DSC01697.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Drop! I mean sit down.
http://3.bp.blogspot.com/_7WfR_akYPWo/S_gQFgrOYvI/AAAAAAAAAjc/iCG2QKNeofI/s400/DSC01698.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Line it up with frame.
http://3.bp.blogspot.com/_7WfR_akYPWo/S_gQFErIHII/AAAAAAAAAjU/DjMZirVS-Sc/s400/DSC01699.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

http://1.bp.blogspot.com/_7WfR_akYPWo/S_gQEizoyfI/AAAAAAAAAjM/mJxl2zrvzR4/s400/DSC01700.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

This spring and pin keep the output shaft connected to the driveshaft.

http://3.bp.blogspot.com/_7WfR_akYPWo/S_gQETyPKkI/AAAAAAAAAjE/ztTxj-XehVk/s400/DSC01701.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

The spring goes inside the output shaft the pin goes in the hole. This lines up with hole in the driveshaft.

http://1.bp.blogspot.com/_7WfR_akYPWo/S_gQDsE0_FI/AAAAAAAAAi8/Cr7zE62x10k/s400/DSC01702.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Like this.

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gPepahQoI/AAAAAAAAAi0/KwS-w73UG78/s400/DSC01704.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Once you get the shaft connected, start with the motor mounts.

http://4.bp.blogspot.com/_7WfR_akYPWo/S_gPeCBZlOI/AAAAAAAAAis/L1Et1NXOwVo/s400/DSC01705.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gPdgC1KcI/AAAAAAAAAik/Cp3E5M4PTxY/s400/DSC01707.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gPdBOTTLI/AAAAAAAAAic/5rqniqP_DgA/s400/DSC01708.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gPc5v4j2I/AAAAAAAAAiU/406K6Cgfy08/s400/DSC01709.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

JPWilliams
05-23-2010, 7:07 AM
Now the radiator and the subframe piece.

http://3.bp.blogspot.com/_7WfR_akYPWo/S_gOpSw3yrI/AAAAAAAAAiM/8hl-Jyr7NRg/s400/DSC01710.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Looking good,

http://1.bp.blogspot.com/_7WfR_akYPWo/S_gOo4erA_I/AAAAAAAAAiE/DyrYARKOdCc/s400/DSC01711.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


oh poop! This brake line ain't routed right. I should have left the brake and floor board connected the subframe, like when I do a clutch spring.
http://4.bp.blogspot.com/_7WfR_akYPWo/S_gOnzE-RPI/AAAAAAAAAh0/Gr33CGXP4bE/s400/DSC01714.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Take off this motormount and take the subframe piece off again.

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gOnHPr7AI/AAAAAAAAAhs/DRTnE4njdEU/s400/DSC01717.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Luckily rubbermounts allow you to pry the motor a bit and sneak the line through.
http://4.bp.blogspot.com/_7WfR_akYPWo/S_gNjYVYhQI/AAAAAAAAAhk/rGHgGMTdE64/s400/DSC01718.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

http://4.bp.blogspot.com/_7WfR_akYPWo/S_gNix3KP1I/AAAAAAAAAhc/X31yXjidEqo/s400/DSC01719.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Okay now we are back together with the motor mounted and the floorboard and brake on.

http://3.bp.blogspot.com/_7WfR_akYPWo/S_gNiS9ztpI/AAAAAAAAAhU/FJJ2hEVE-Dw/s400/DSC01721.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Mount the dirty rectifiers.

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gNhNfPC8I/AAAAAAAAAhM/LgIL-eM8z7Q/s400/DSC01723.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Oh poop, again! We should have routed the hydraulic clutch correct before we bolted the motor in. It should go behind the motor and up through that hook.


http://4.bp.blogspot.com/_7WfR_akYPWo/S_gNgsj_vsI/AAAAAAAAAhE/-pAbilnynDQ/s400/DSC01724.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Yeah there's not way we can cheat this one through. I have fresh banjo seals, because I we'll be putting steal lines on soon and I have a new seal for the leaky slave cylinder. So we took the slave cylinder off and routed the line corrected.

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gMq_mkNMI/AAAAAAAAAg8/wEovsgBY9Vw/s400/DSC01725.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Here's the piston for the slave cylinder
http://1.bp.blogspot.com/_7WfR_akYPWo/S_gMqUWNZHI/AAAAAAAAAg0/qfOqKcVHIJU/s400/DSC01727.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gMp20AoBI/AAAAAAAAAgs/a24_zSGEKNc/s400/DSC01730.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)
New seal.

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gMpTXO7kI/AAAAAAAAAgk/IH8UYXXotgA/s400/DSC01731.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Put everything back together and bleed the clutch line.
http://3.bp.blogspot.com/_7WfR_akYPWo/S_gMo3BZ1FI/AAAAAAAAAgc/vAGSQ-pvoFc/s400/DSC01732.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)
Mighty vac!
http://4.bp.blogspot.com/_7WfR_akYPWo/S_gLtpof5GI/AAAAAAAAAgU/mL8apPOta6o/s400/DSC01733.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)



Now to the carb.
http://2.bp.blogspot.com/_7WfR_akYPWo/S_gLtM_bGHI/AAAAAAAAAgM/oS5f4k_Dog0/s400/DSC01734.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Connect the plate and the cables.

http://3.bp.blogspot.com/_7WfR_akYPWo/S_gLstrC9LI/AAAAAAAAAgE/wwW7aN7gy8A/s400/DSC01736.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Gas inlet.(that's important.) Now how does this choke cable route? (over the top of the rear jug, thanks Nate.)

http://2.bp.blogspot.com/_7WfR_akYPWo/S_gLsCED8BI/AAAAAAAAAf8/2kgoZ8KchRM/s400/DSC01738.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Carb in the boot.
http://4.bp.blogspot.com/_7WfR_akYPWo/S_gLrrgrRwI/AAAAAAAAAf0/VkD3tfKaRAM/s400/DSC01739.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

Breather coming together.

http://3.bp.blogspot.com/_7WfR_akYPWo/S_gKFVr7Q8I/AAAAAAAAAfs/VZ-G1zCt8nI/s400/DSC01742.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)
http://4.bp.blogspot.com/_7WfR_akYPWo/S_gKExZWOCI/AAAAAAAAAfk/-UAr2D75fBA/s400/DSC01744.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Cover on.
http://2.bp.blogspot.com/_7WfR_akYPWo/S_gKEWTeuwI/AAAAAAAAAfc/qwwW7vJ66gk/s400/DSC01745.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Now for the pipes.
http://1.bp.blogspot.com/_7WfR_akYPWo/S_gKD6yDEXI/AAAAAAAAAfU/1hL-DV_Engg/s400/DSC01746.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)


Now the engine looks good, but I definately need to de-chrome the rest of this thing, but I'm holding off until the engine runs and I have the money for more powdercoat.
http://3.bp.blogspot.com/_7WfR_akYPWo/S_gKDQGnBDI/AAAAAAAAAfM/t5XqGAX9dKs/s400/Photo-0041.jpg (http://tearitupfixitrepeat.blogspot.com/2010/05/engine-in-to-frame.html)

JPWilliams
05-23-2010, 7:50 AM
Almost done.

Hotsauce came by to help. He unplugged the electrical connections under the left cover and filled them with dielectric grease. He's seen a few of these melted down and this should help.
http://4.bp.blogspot.com/_7WfR_akYPWo/S_kseCUseKI/AAAAAAAAAm0/ZF1w9KibRlU/s400/DSC01748.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/finishing-vulcan-motor.html)

What's this green stuff? Antifreeze? You mean like in a car?
http://3.bp.blogspot.com/_7WfR_akYPWo/S_ksdslFyQI/AAAAAAAAAms/dk3hk860yWQ/s400/DSC01751.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/finishing-vulcan-motor.html)

New oil filter. (It helps to use the right one, because my mini-van oil filters are about the same size, but they don't fit no matter how hard you try.)
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Don't forget to put oil in it.

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Yea! I get to use my new I.V. gas tank.

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Hook up the dash.
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LIGHT IT OFF!
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The battery is a touch weak so we charged for a bit and tried again.

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Runs better than new. Get it warm and burp the coolant.

Finish it up.
Left cover.

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Toe shifter.

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Heel shifter.
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Floorboard.
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Dash and Tank. Empty the IV bottle, too.
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Ready for a test drive. Pat and Hotsauce laughed at me because I didn't a jacket, too.
http://2.bp.blogspot.com/_7WfR_akYPWo/S_kqeH0yndI/AAAAAAAAAlU/gH7ylUdP8bY/s400/DSC01772.JPG (http://tearitupfixitrepeat.blogspot.com/2010/05/finishing-vulcan-motor.html)
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JPWilliams
06-13-2010, 7:38 AM
I lowered it, to get ready to bob the fender. It wasn't difficult, but I'll spare you the details. You can check my blog though.

http://tearitupfixitrepeat.blogspot.com/2010/06/lowrider.html

<a href="http://smg.photobucket.com/albums/v74/jfnp52/Vulcan/?action=view&amp;current=DSC01968-1.jpg" target="_blank"><img border="0" alt="Photobucket" src="http://img.photobucket.com/albums/v74/jfnp52/Vulcan/DSC01968-1.jpg" /></a><a href="http://4.bp.blogspot.com/_7WfR_akYPWo/TBAnFm33DUI/AAAAAAAAApI/7UygXH208WA/s1600/DSC01979.JPG"><img style="WIDTH: 400px; HEIGHT: 300px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5480923723797564738" border="0" alt="" src="http://4.bp.blogspot.com/_7WfR_akYPWo/TBAnFm33DUI/AAAAAAAAApI/7UygXH208WA/s400/DSC01979.JPG" /></a>

JPWilliams
06-13-2010, 7:43 AM
I wanted to powdercoat the rims of my wheels to match the "aluminum blast" that I put on the motor, so went and got my spare wheels from the shed. My buddy Panhead Pat is going to help me break down the spoke and teach me to re-lace. To my surprise they still had tires on them. I forgot about that. The sad thing is that the tires on my spare rims were a little nicer than ones on my bike now.
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So this is how I take my tires off. Take the valve core off.
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Take the lock nut off the valve stem.
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Time to break the bead. Now this the part I'm proud off. I designed and build this bead breaker myself. I based it off the two internet ideas I saw. One used a huge lever and wedge attached to a wall stud and the other used a big hydraulic press from Harbor Freight. Both of those options were too big to mess with and use one a year or so on tires. So here it is.

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Homemade 2x4 frame and wedge.

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Now to the hydraulic part. A little bottle jack from Harbor Freight less than $20. (I carry this in my car to fix flats too.)

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The first bead is easier than the second. I usually have to press against the rim on the opposite side to get it off, but it doesn't hurt anything.

Now the frame holds the wheel to get the tire. This helps when the wheels still have a brake rotor on them,
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I use three irons. I really like the skinny one with the handle to run point. Then the other two hold things still so the tire doesn't jump back into the rim.

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Once the tire is off the side, pull the inner tube out.

http://4.bp.blogspot.com/_7WfR_akYPWo/TBTSyWasMyI/AAAAAAAAAqY/wWnpCnJWEeg/s400/DSC02030.JPG (http://tearitupfixitrepeat.blogspot.com/2010/06/dismounting-tires.html)

Now to the other side. I turn it up and get it started, then rip it off.

http://3.bp.blogspot.com/_7WfR_akYPWo/TBTSxwFJwvI/AAAAAAAAAqQ/A2O2YwUVYXM/s400/DSC02032.JPG (http://tearitupfixitrepeat.blogspot.com/2010/06/dismounting-tires.html)


Now do the front tire and wheel the same way. Tires are hard work, but you feel like a real man when you're done.

JPWilliams
06-25-2012, 6:31 PM
Don't use Facebook for image hosting. My earliest stuff has all fallen victim to broken links. I redid this write-up here. http://tearitupfixitrepeat.blogspot.com/p/v-behaviorurldefaultvml-o.html I cleaned it up and organized a bit better. I'm not trying to take away from chopcult. I just wanted to share the info