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  1. #1
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    Default 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
    Click image for larger version. 

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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 at 9:10 PM.

  2. #2
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    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 at 9:22 PM.

  3. #3
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    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 at 9:28 PM.

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

  5. #5

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

    Jim

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    Its an 80

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    Quote Originally Posted by JBinNC View Post
    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.

  8. #8
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    Quote Originally Posted by jcrubin View Post
    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 Thumbnails Attached Thumbnails MVC-015S_zpsef848745.JPG  

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    Quote Originally Posted by Tattooo View Post
    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

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

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

  12. #12
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    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 at 9:05 PM.

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

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

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    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 at 8:22 AM.

  16. #16

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    Quote Originally Posted by jcrubin View Post
    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.
    Motor mount bolts should be 3/8-24, grade 5, hex cap screws of sufficient length to fully engage a nylon insert lock nut.

    Jim

  17. #17
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    Quote Originally Posted by JBinNC View Post
    Motor mount bolts should be 3/8-24, grade 5, hex cap screws of sufficient length to fully engage a nylon insert lock nut.

    Jim
    Yes, this was apparent upon removal and the correct ones will be used in the re-installation, that said it looks like the mounts are a bit out of round.. Makes me wonder if this is an issue, and if so if there is a jig to cut and press a sleeve into these if this is a known issue


    FR




    FL




    RR




    RL
    Last edited by jcrubin; 01-27-2019 at 7:48 PM.

  18. #18
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    ^^^^ Is that grease in the front holes it looks like it is??^^^^^^ it's hard to tell.......

    See if it is???? If it is clean in out your old bolts were to small........

  19. #19
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    Quote Originally Posted by Tattooo View Post
    ^^^^ Is that grease in the front holes it looks like it is??^^^^^^ it's hard to tell.......

    See if it is???? If it is clean in out your old bolts were to small........
    I will clean out the holes and retake the photos, Its fully established that the bolts that i removed were not OEM and were too small. The question is dealing with out of round mount holes.

  20. #20
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    Quote Originally Posted by jcrubin View Post
    I will clean out the holes and retake the photos, Its fully established that the bolts that i removed were not OEM and were too small. The question is dealing with out of round mount holes.
    I'll bet if you get the grease or what ever out the holes they will be round enough....

    Just remember when your remounting/bolting down the motor it might need to be shimmed and you should mount the inner primary to the trans and motor before anything is tightened down.....

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