It was a good run, I got 40K out of my bike before any major repairs were needed.

I took my time, and followed the advise of my mentors and the manual and made the needed repairs. I now have a bike that I love and is ready for another 40K if not more.

The repairs I made - I did my due diligence, and IMHO, I chose the strongest, most durable, replacement parts I could find.

On the last day of assembly, I worked late into the night to finish it, that decision bit me in the butt. I made some mistakes, I overlooked a small gasket in the rear cylinder rocker box. I also didn't get the bottom O-ring in the rear intake push rod tube seated properly. Both leaked oil profusely. I had to prop the gas tank up to access the rear rocker box. As soon as I got it opened, I saw the gasket was missing. I found it mixed up with the old ones. I cleaned it up good as new placed it into position and buttoned it back up. While I had it open I double checked all my torque specs - they were all good.

I didn't know the O-ring was leaking until after I got the rocker box right. I took her out for a test ride around the block a few times and everything looked OK & sounded OK. So I went for a little longer ride over to my buddies house. Once I got to his place I saw some new splatters on the starter cover. couldn't tell where it was coming from -still, she wasn't right yet. Once I got home, I wiped everything down and let it run in the driveway until I could diagnose it. Found the problem, shut it down, let it cool down. Popped the tube open and saw the bottom O ring wasn't sitting properly. Straightened it out, put everything back together and took it out for a test ride. Looked good. Took it out on the freeway - it held. Took it back home, got the simple green out and scrubbed down the engine with a tooth bush. Yeah the black wrinkle paint is faded but the engine looks like new.

The bike runs better than ever. The new cam is amazing. It has tree stump pulling torque. I lugged it in 3 and then in 4th and then in 5th... It's like an electric motor it just pulls. Bike runs better now. I was told when I bought the bike that the carb had been re-jetted. When I re-jetted it to match the new cam I found out that it was never touched. So now it runs even better than before I had to repair it.

Here's the final parts list to get her back up and running.

New parts:
Oil Pump
Cam & Cam Bearing
Tappets
Tappet Guide Blocks
Push Rods
Slow Jet
High Speed Jet

I also replaced all the remaining factory fuel lines while I had the carb off. I upgraded the leaking and broken plastic covered brass L fuel inlet fitting to a solid brass one.

So now the bike has all new rubber in the fuel system, fresh engine, stronger and faster than new.
I think she's ready for another 40K!!

Some more Pics of repairs...

Well Hell...Looks like its time to ride. Just got the new camera in and need to test it out. If Paul's ready we need to hit the road even if it just a short run..

Your bike is looking great RK. Thanks for sharing your journey. I think you will get a lot more than another 40k from here.

lookin good, got to use that adjustable pushrod real quick I see. If you want those cases lookin like brand new just buy a can of S100 engine brightner read the directions and you are good to go, cases like brand new. Don't tell anyone though, it is my secrete.
DEERSLAYER

500 miles of break in, after that we can do Harleys in a Hurry II

Paul's ready. He wanted to go Sunday but I had other plans. Mike is ready too. We can do a PCH south to Ortega to elsnore to tom's farm for luinch then back the way we came. That keeps us off the Frwy and still kinda not too far for all concerns. Dang's first words were "It's about Time!!" when I got over to his house.
I think we're all ready for a good ride!!



Thank You Brother!! It's been a journey to say the least. But then it was the learning curve more than anything else. Remembering how to do the work after not having to do anything of this magnitude for a long time. Plus, this was a solo experience. I had a couple very knowledgeable people to ask, but I had to do all the actual work. Not like I could say, "HEY DeerSlayer, come on over and show me what to do!!" He was nice enough to let me bend his ear and pick his brains, Thanks again for that!!
Thing is, once it's done as I look back on it - really - it was straight forward and fairly easy. The stress came from the unknown element, and that unspoken question... will it run when I'm done?

Well she does run!! After I let my brother take it out for a ride he said to me "it runs great - you did a good job" my staunchest critic has spoken and given me the thumbs up.

Yeah if it's not all hype - and the new parts are as good as they say they are she should be good on that side of the engine for a lot longer than 40K!!

Thank You Sir!!
Yeah, the adjustables are a breeze, also makes it easy for the next time - when that comes.
I will get some - thanks for the tip - and don't worry I won't tell anyone else, I'll keep your secret

Jetting the carburetor was just replacing a couple of jets.
Knowing what they look like might help so here's the pics I forgot to post yesterday.

I got the jets at the local shop - they were competitive and I needed a couple of special blind rivets to re-attach my medallion.

The old ones.
The old ones and the new ones
The new ones installed