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My build thread and my troubleshooting threads all disappeared along with the past year's worth of posts on this site. I'm going to blame the Russians. What better way to attack freedom loving Americans than fuck with a chopper site? For reference, this is my build:
It's a 1978 FLH I pieced together from parts and has never run as a complete bike.
I had/have three problems getting it road-ready: (1) it wouldn't idle, (2) the kicker jams, and (3) oil leak.
I finally solved the idling problem tonight.
I have it timed so it starts on 1 or 2 kicks (when the kicker doesn't jam), but it wouldn't idle for shit. I had to keep a little throttle on and blip it or it would die, back firing through the carb. All the answers I found were "too lean," "too advanced," and "manifold leak." I pulled the carb, replaced the gaskets, and swapped out the band and aircraft clamps for a Tite-seal kit. Nothing changed. I got it running and blew propane all over it. Nothing. It's a Harley CV carb, and I had it set at 1 3/4 turns out in the mixture screw. I have a 3-position choke, and had the choke all the way out. I kept turning the screw out until I had 4 1/2 turns out. Still wouldn't idle and kept farting through the carb at low rpms. So, now I was thinking that the passageways in the carb are clogged (even though I cleaned the crap out of it) and I'll have to take it all apart again. As a last ditch effort, I turned the mixture screw all the way in and pushed the choke all the way in. It fired right up and idled beautifully. Seems it was too rich. I should probably order a size smaller jet, but I'm just going to run it and see if I really need to.
Regarding the kicker jamming, I replaced my Taiwanese kicker gears with Baker's after I sheared off the key (see pic below), and it still jams about 3 out of 4 kicks. I checked for interference on the motor side (plugs vs. valves) and that wasn't the problem. Something is still jamming up, and I can hear it coming from the transmission (or clutch, but I can't imagine what in the clutch would cause it). The transmission shifts fine with no binding, and I verified that it is not popping into gear or anything like that. When I take the plugs out, it kicks over fine with no jamming, but every once in a while, it seems to slip or bind just a bit. I'm suspecting that there is something out of spec with either the kicker cover (V-twin) or the kicker gear shaft (also V-twin). I've learned that the motor starts so easily (when it doesn't jam) that I really don't have to kick hard at all. That will at least prevent me from breaking something until I get it figured out. I think I might try to find an OEM or S&S kicker cover and a better (Jims?) shaft. I may start saving up for a Baker 6-in-4.
Finally, the oil leak. It was leaking pretty bad when I had it running the past few days (before I fixed the idling problem), but because I had to stay on the throttle, I couldn't figure out where it was coming from. It seemed to be from the oil pump, and I suspected a gasket leak. Then, I realized that I never blocked off the primary chain oiler outlet. I fixed that with a machine screw and teflon tape.
I haven't cleaned my garage floor yet from the leaking, so when I got it idling well tonight, I wasn't sure if the puddle under it was from before or not. I'll have to clean the floor up (or lay down some cardboard) and figure out if it's still leaking and from where. But, at least now I can get it on the road. My plan is to test ride it this weekend after I hook the clutch release back up.
It's a 1978 FLH I pieced together from parts and has never run as a complete bike.
I had/have three problems getting it road-ready: (1) it wouldn't idle, (2) the kicker jams, and (3) oil leak.
I finally solved the idling problem tonight.
I have it timed so it starts on 1 or 2 kicks (when the kicker doesn't jam), but it wouldn't idle for shit. I had to keep a little throttle on and blip it or it would die, back firing through the carb. All the answers I found were "too lean," "too advanced," and "manifold leak." I pulled the carb, replaced the gaskets, and swapped out the band and aircraft clamps for a Tite-seal kit. Nothing changed. I got it running and blew propane all over it. Nothing. It's a Harley CV carb, and I had it set at 1 3/4 turns out in the mixture screw. I have a 3-position choke, and had the choke all the way out. I kept turning the screw out until I had 4 1/2 turns out. Still wouldn't idle and kept farting through the carb at low rpms. So, now I was thinking that the passageways in the carb are clogged (even though I cleaned the crap out of it) and I'll have to take it all apart again. As a last ditch effort, I turned the mixture screw all the way in and pushed the choke all the way in. It fired right up and idled beautifully. Seems it was too rich. I should probably order a size smaller jet, but I'm just going to run it and see if I really need to.
Regarding the kicker jamming, I replaced my Taiwanese kicker gears with Baker's after I sheared off the key (see pic below), and it still jams about 3 out of 4 kicks. I checked for interference on the motor side (plugs vs. valves) and that wasn't the problem. Something is still jamming up, and I can hear it coming from the transmission (or clutch, but I can't imagine what in the clutch would cause it). The transmission shifts fine with no binding, and I verified that it is not popping into gear or anything like that. When I take the plugs out, it kicks over fine with no jamming, but every once in a while, it seems to slip or bind just a bit. I'm suspecting that there is something out of spec with either the kicker cover (V-twin) or the kicker gear shaft (also V-twin). I've learned that the motor starts so easily (when it doesn't jam) that I really don't have to kick hard at all. That will at least prevent me from breaking something until I get it figured out. I think I might try to find an OEM or S&S kicker cover and a better (Jims?) shaft. I may start saving up for a Baker 6-in-4.
Finally, the oil leak. It was leaking pretty bad when I had it running the past few days (before I fixed the idling problem), but because I had to stay on the throttle, I couldn't figure out where it was coming from. It seemed to be from the oil pump, and I suspected a gasket leak. Then, I realized that I never blocked off the primary chain oiler outlet. I fixed that with a machine screw and teflon tape.
I haven't cleaned my garage floor yet from the leaking, so when I got it idling well tonight, I wasn't sure if the puddle under it was from before or not. I'll have to clean the floor up (or lay down some cardboard) and figure out if it's still leaking and from where. But, at least now I can get it on the road. My plan is to test ride it this weekend after I hook the clutch release back up.
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