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  1. Could be any number of things, starting with the...

    Could be any number of things, starting with the mainshaft ball bearing nut being loose, all the way out to the kick cover itself, if it's not machined properly.

    Jim
  2. Mainshaft starter gears often come these days...

    Mainshaft starter gears often come these days with yellow brass bushings. These should be avoided at all costs because they simply will not run for long,and they run hot. The bushing should be...
  3. OK, here's your warning: Those ratchet teeth...

    OK, here's your warning:

    Those ratchet teeth are touching when the motor is running, and they are getting hot. I have seen one instance where the ratchet teeth got so hot they welded themselves...
  4. Edge of the oil dripper. Picture is sideways(?) ...

    Edge of the oil dripper. Picture is sideways(?)

    Jim
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    A resonant "boing" sound is usually a valve...

    A resonant "boing" sound is usually a valve spring, from a valve sticking or hitting something in the combustion chamber. Example, long reach plugs in short reach heads, and the edge of the intake...
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    Intake seals at the head and carb could be...

    Intake seals at the head and carb could be allowing a vacuum leak when hot. Also look for a cracked intake flange.
    In hot weather, you could be getting vapor lock after a hot soak, but I don't know...
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    Get a better cover. The KromeWerks baffles are...

    Get a better cover.

    The KromeWerks baffles are considered state of the art.

    Jim
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    Those early dual disc brakes were marginal at...

    Those early dual disc brakes were marginal at best, so taking away half the braking is not a great idea.

    But, if you must, it is straightforward as you say, except that to have any front brake...
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    Cycle Electric components are hard to beat. At...

    Cycle Electric components are hard to beat. At one time they were supplying H-D rotors with their kits. You could just buy the stator from Cycle Electric and the rotor from your dealership.

    But...
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    ^^^This, all day long ^^^ The bike is no...

    ^^^This, all day long ^^^

    The bike is no "survivor." It appears to be recent, so do with it what you will. Making it roadworthy and getting the paperwork in order would be your first steps. Ride...
  11. Ignition switch should NOT have ANY post...

    Ignition switch should NOT have ANY post grounded.
    That's mistake #1.

    Jim
  12. Studs are available in 1st, 2nd, and 3rd...

    Studs are available in 1st, 2nd, and 3rd oversizes, because this is common. The bosses in the transmission base are not deep, and moisture in the oil works at the aluminum/ steel interface to cause...
  13. The baffle location will affect the overall...

    The baffle location will affect the overall "tune" of the motor. The only way to know which position is best is by test, which means you may have to disassemble/ assemble it up to 3 times. And, you...
  14. Ha! In the past, there was no testing at all, no...

    Ha! In the past, there was no testing at all, no license endorsement, no training course, nothing. You bought or borrowed a motorcycle and learned to ride it on your own, or if you were lucky, your...
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    The original lines had very close bends at the...

    The original lines had very close bends at the tank. I would suggest that you buy a good set of replacement lines, and cut the line near the oil pump with a short rubber line for a connection. Note...
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    Now comes the hard part, tracking down the...

    Now comes the hard part, tracking down the offending piece.

    Jim
  17. I believe the factory riser is cast steel, but...

    I believe the factory riser is cast steel, but because the riser and the tubing (or round bar) are different alloys, I thought the brazing would be most foolproof.
    Disclaimer: I am not a welder, I...
  18. Autocorrect screwed me again. Braze, not...

    Autocorrect screwed me again.

    Braze, not braise.

    Jim
  19. TIG braise it. Jim

    TIG braise it.

    Jim
  20. Replies
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    I would be looking at the primary circuit for the...

    I would be looking at the primary circuit for the ignition:
    Battery cables
    Main breaker
    The small wire from batt pos. to the main breaker
    Ignition switch
    Run/off switch
    Ignition breaker ...
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    Since the kick clutch teeth look like they are...

    Since the kick clutch teeth look like they are engaged fully, it's possible that the kick clutch is spinning on the mainshaft. (That would be very unusual, they usually lock on the taper pretty...
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    Don't tear it down. 75 psi, only kicking is a...

    Don't tear it down. 75 psi, only kicking is a little weak, but enough for a running motor, especially since the readings are the same.

    Replace the condenser, look at the advance unit for damage...
  23. I often put the stock clutch in, leaving out the...

    I often put the stock clutch in, leaving out the spring plate and adding two steels and a fiber disc (my own "extra plate") and I've never had any trouble squeezing it all in.
    I suppose your only...
  24. Spring seat under lock ring upside down? Jim

    Spring seat under lock ring upside down?

    Jim
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    I believe your motor to be an '80 or '81. There...

    I believe your motor to be an '80 or '81. There are "belly numbers" on the cases, that are the same for each case half unless one has been replaced. On your left case that number should be in the...
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