Thursday, January 31, 2013

Got the engine into the frame tonight. Next step is to make the exhaust, which I really should have done before I powdercoated the frame.... oh well. I'll cover up everything as much as I can to protect it from the welding slag. It will only be tacked together while it's on the engine/frame so it shouldn't be that bad.


Tuesday, January 29, 2013

OK it's been a week but lots have been completed. The engine is together, clutch side cover is sanded, and the carbs cleaned up and re-jetted as well.


I decided that at this point I would be able to get it running pretty easily without troubleshooting it in the frame. I used a scrap piece of sheet metal and mounted 2 coils and the condensers to it, then ran an extra ground from the sheet metal to the block. Next I found some larger gauge wires to run a ground from the block to the battery and from the + terminal on the battery to the starter power terminal. I also had to use the points for this setup. When the engine is in the bike I will be using an upgraded electronic trigger with a dual output coil instead of points and 2 coils. This will be much more reliable.



Once this was setup I tried over a course of several evenings to try and get it to run but it just wouldnt fire up. Very frustrated I verified over and over all the usual suspects: timing, points gap, points timing, electrical wiring, spark, carb adjustments, etc, etc.

Today at work it hit me, why wont it even sput if I am getting fuel and spark with good timing??? Well if the points shaft is off 180* then the left coil will spark on the right cylinders timing (and right to left). So I got home tonight and checked the points advance lobe position at TDC......

WRONG

RIGHT!

Things were now looking good. So I threw the tank on top of the trash can and hooked up the fuel. Took a few cranks to get fuel flowing through the carbs, 2 putts and BAM running like a champ!!! It pops a bit because the spark is a little intermittent, the new trigger won't do that. 



Tuesday, January 22, 2013

Finally got the last spoke in for the rear wheel. Threw it in the other day and trued it up last night. One of the garage lights blew so these pics aren't that great.



Sunday, January 20, 2013

Progress report: cylinders were deglazed (thanks Dad for the reminder), new rings are on, jug was scrubbed,  valves were lapped, cylinder head and combustion chambers were cleaned too. Main engine components are now assembled and torqued.




Friday, January 18, 2013

Nothing exciting to update but the other night I split the lower case, replace the crank and transmission output seals then closed it up with gray RTV. Last night I got the bottom end finished up with installing the sump filter, cleaning the sump cover, new copper washers and re-tapped the holes. Starter is in with a new seal and the clutch is in with a new 1 piece pushrod from an earlier model (mine had a 2 piece pushrod with a ball bearing in between the halves). 

I hope that tonight I can get the pistons cleaned up, new rings on, and the top end all buttoned up.


Order of things to follow:

1. Finish engine (duh)
2. Re-build carbs. New gaskets and new jets (pilots and mains) one size up
3. Maybe try and fire it up on the engine stand???
4. Install into the frame and build the exhaust
5. Assemble the electronics housing and wire it up
6+ lets get 1-5 done first...

Saturday, January 12, 2013

Friday, January 11, 2013

Was able to get the engine stand adapters finished last night and all mounted up. Just called the powdercoating guy and the frame is ready!!! He did the frame, fork trees, and front engine mount all gloss black. Going to pick it all up 10am tomorrow morning.




Monday, January 7, 2013

Small update: frame is at the powdercoater, he says he's going to work on it this week and have it ready by this weekend. We'll see how that goes. I made brackets to mount the engine onto the engine stand. Tonight I will try and get it all mounted up. I also trued the front wheel and mounted the tire. Looks fantastic!