The FXS Shovelhead rebuild project

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  • jcrubin
    Member
    • Dec 2018
    • 93

    The FXS Shovelhead rebuild project

    Well underway is this project that I had initially thought was a burned up exhaust valve, which turned into so much more. Im documenting the entire adventure and will be posting as a series to my youtube channel in short order. As it stands, now, a bottom end rebuild, and some possible tranny work.... so it goes... its fun work...

    Setting up for video work
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    Disassembly begins
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    Exhaust valve guide and seat



    Rear piston, oil came from head downward



    Front piston oil blow-by, victim of ring alignment caused by piston slap
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    Oil drain port vs. Gasket diameter [James]



    Oil leaking through rear exhaust valve



    Head reassembly after work done



    Rocker polish 1



    Rocker polish 2



    Rocker polish 3



    Rocker polished 4



    Rocker polish rouge
    Last edited by jcrubin; 01-16-2019, 8:10 PM.
  • jcrubin
    Member
    • Dec 2018
    • 93

    #2
    Tranny cleanup



    Tranny clean



    Piston wear



    Side slap



    Other side



    Cylinder wear



    Wrist pin wear



    Wrist pin out of round



    Broken oil bag mounts
    Last edited by jcrubin; 01-16-2019, 8:22 PM.

    Comment

    • jcrubin
      Member
      • Dec 2018
      • 93

      #3
      Which side is it leaking from



      Official locking tool



      Basket removed



      Leaking from both sides



      Inner - OFF



      Tranny leak also apparent
      Last edited by jcrubin; 01-16-2019, 8:28 PM.

      Comment

      • Tattooo
        Senior Member
        • Sep 2012
        • 12407

        #4
        Man that looks very nice.... What year FXS???

        Comment

        • JBinNC
          Senior Member
          • Dec 2018
          • 2697

          #5
          Your piston skirt wear pattern shows the rods were not aligned before the top end was installed. Don't skip that step yourself.

          Jim

          Comment

          • jcrubin
            Member
            • Dec 2018
            • 93

            #6
            Its an 80

            Comment

            • jcrubin
              Member
              • Dec 2018
              • 93

              #7
              Originally posted by JBinNC
              Your piston skirt wear pattern shows the rods were not aligned before the top end was installed. Don't skip that step yourself.

              Jim
              Im pulling the motor as both wrist pin bushings worn out point towards a crank pin wear issue most likely, though other things may also be suspect, they will be identified.

              Comment

              • Tattooo
                Senior Member
                • Sep 2012
                • 12407

                #8
                Originally posted by jcrubin
                Its an 80
                That's awesome..... Here's my 79 FXS.....

                Your rocker boxes are much better than most that I've seen of that era..... Mine were pitted like hell.... That's what they were painted....
                Attached Files

                Comment

                • jcrubin
                  Member
                  • Dec 2018
                  • 93

                  #9
                  Originally posted by Tattooo
                  That's awesome..... Here's my 79 FXS.....

                  Your rocker boxes are much better than most that I've seen of that era..... Mine were pitted like hell.... That's what they were painted....
                  With the original airbox, wow

                  Comment

                  • Tattooo
                    Senior Member
                    • Sep 2012
                    • 12407

                    #10
                    Originally posted by jcrubin
                    With the original airbox, wow
                    Also it's only got 16,000 miles and the original paint.....

                    Comment

                    • jcrubin
                      Member
                      • Dec 2018
                      • 93

                      #11
                      As one of the many side projects, tried out NORD-LOCK washers for the side cover of the tranny at 190in/lbs

                      Comment

                      • jcrubin
                        Member
                        • Dec 2018
                        • 93

                        #12
                        Leaky tranny




                        Leaky tranny 2




                        Some say this is a sign of a loose sprocket




                        But it was torqued to spec and the lock tab is still in place




                        Engine mount stud wear 1




                        Engine mount stud wear 2




                        Empty....




                        Along side 1




                        Along side 2




                        Benched




                        Stator crack and wire rot




                        Unspeakable....!
                        Last edited by jcrubin; 01-26-2019, 8:05 PM.

                        Comment

                        • Tattooo
                          Senior Member
                          • Sep 2012
                          • 12407

                          #13
                          Damn it....^^^^^^ That bike has had a very hard life......

                          Comment

                          • Bbqbiker
                            Senior Member
                            • May 2015
                            • 2394

                            #14
                            Wow 39 years of wear if that’s the orig. Nce work keep the pics coming. Have you ordered your 93” Sidewinder setup yet???

                            Comment

                            • jcrubin
                              Member
                              • Dec 2018
                              • 93

                              #15
                              Top end stuff is 7 years old, bottom end stuff is 40 years..... Id say it did ok... Ill admit I did reuse the stator. IT DID NOT look like that when i put it back in, in the last 7 years it somehow got corrupted and oxidized.

                              When I look at the mounting bolts I cant help but think they are uhm, well ,,,, wrong?

                              At a minimum, given the wear location, you think the bolts would be wider and have the thread start further down the shaft. The fact that the hex bolt was metric leaves me suspicious.
                              Last edited by jcrubin; 01-27-2019, 7:22 AM.

                              Comment

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