Engine - Part I

July 25, 2012

I tore into the engine after work.  The head came off easy, but the cylinder jug needed some convincing to break free.  I sprayed a bunch of liquid wrench in the stud holes and around the outside of the gasket, then tapped it with a mallet.  Its scary to tap those dinky fins, but a good tap on the front where the exhaust port is, finally did the trick.

Once I removed the cylinder, I stuffed a rag in the engine and went on to clean the carbon deposits off the piston, but later realized there was too much carbon bellow the rings.  Did some reseach since I don't know shit, and found out this is a sign of blow by, and I decided i should probably rebuild the top end.  Might as well do it right, while the engine is out, besides its probably never been done.

Now I need to figure out if the cylinder bore needs to be honed, if so how much, and how to know what size (oversize) piston and rings to buy.

Found a motorcycle shop near my house with good reviews, so I might leave this one to the pro's.

July 26, 2012

I went to my friends house and we tore into the engine a little bit more.  Spent about an hour scraping gaskets, and then took the left case off to reveal a pretty messed up sprocket.  We put some new gaskets in, still got some more work to do today or tomorrow. 

There was a lot dirt and mud in there

Here is my damn $60 sprocket

July 27, 2012

I went back to my friends house and put the engine back together just to get it home.  I will have to take the side plate off again to get the new sprocket in, once it arrives.

Took the oil pump off just to check it out. 

Engine - Part II

July 29, 2012

Did some prep work, not as good I should have done, and then painted part of the engine.  Used Dupli-Color Engine Enamel.

July 30, 2012

My new sprocket came in and is now on the engine.  I finished painting the engine, and it should be ready to go back on when I get home from work today.  I changed my mind again on rebuilding the top end, im just putting it in and we'll see what happens.

Final Assembly

July 31, 2012

I rolled the bike out today and put it all back together.  Engine, new spark plug, exhaust, battery, air intake with new filter, new chain, filled the fluids, filled the gas tank, etc.

Gave it a Kick....and nothing!  It cranks but its not starting.  Leaks a ton of gas out the carburetor overflow.  I tried tinkering with it until it got dark.  I'll try again today, might have to order a carb repair kit.  The anticipation is killing me, I just want it to start!

One thing is for sure, it looks pretty damn good!

Ghetto stand, milk crate, old cutting board, and old bath mat.

I have to so something about the kick stand, its too loose, and allows the bike to tilt over more than i want it to.

Wiring Diagram

August 1, 2012

I tried again to get the bike started, cleaned out the carb, soaked the air filter in gas, did a float test on the carb float.  I will have to check the electrical next,  I have a few wires that were not connected when I got the bike so I started looking for a wiring diagram.

Found this on the last page of the Riders Handbook

Now that I think of it, the battery and coil ground to the frame and the powder coat on the frame could be interfering with the connection.  I will try to remove the powder where those touch to get a proper ground, then try doing a spark test.

Rider's Handbook

There's some great info in this handbook, I will scan a few pages when I get a chance.

Update: 2/14/17

Heres a video I made flipping through the pages...

https://youtu.be/ycGGqp1IGNQ

Update: 2/15/17

The video quality sucked, so I went ahead and scanned this sucker, check it out...