Decent trade for Purple Combat

Head is inverted, so right cylinder is on the left. THIS is where the problem was.

Decent trade for Purple Combat


Right cylinder is badly stuck, left side not too bad (that's WD-40 in there).

Decent trade for Purple Combat


The head will clean up real easily.

Decent trade for Purple Combat


Right cylinder is basically trash.

Decent trade for Purple Combat
 
Cam lobes look fair, no severe wear, just the typical uneven factory finish.

Decent trade for Purple Combat


These lobes are in good shape. Cam followers aren't flat spotted at all, so that's a big plus.

Decent trade for Purple Combat


Right piston was well and truly stuck. Also evidence of severe blow-by.

Decent trade for Purple Combat


Left piston is not bad at all, it was on the compression stroke with both valves closed, so no moisture ingress damage. Still has severe blow-by damage.

Decent trade for Purple Combat


These are NOT the dreaded "pop top" sliced pistons, thankfully.
 
Transmission is uncharacteristically clean, no milky mess, very little rust. That's big.

Decent trade for Purple Combat


There were no cush rubbers in the rear hub. Clack, clack, clunk!

Decent trade for Purple Combat


Rear fender & wheel removed (temporarily on the wheel)

Decent trade for Purple Combat
 
Stripped off the wiring harness, oil filter, cooler & hoses.

Decent trade for Purple Combat


All levers, cables, and front brake removed.

Decent trade for Purple Combat


Clutch was pretty heavily contaminated with thick tranny lube.

Decent trade for Purple Combat
 
Nice surprise - ShurFlex lightweight composite clutch friction plate$!

Decent trade for Purple Combat


It's always nice to see the inside plate still securely pinned in place.

Decent trade for Purple Combat


"Flip Side"

Decent trade for Purple Combat
 
Primary didn't put up too much of a fight, I did have to employ the puller to get the engine sprocket free.

Decent trade for Purple Combat


That's as far as it's going, bare rolling chassis to be scrubbed and touchup painted with gloss black Rust-O-Leum rattle cans.

Decent trade for Purple Combat


End of another long day...
 
That's a lot of work in a short time.
What do you use to keep the gearbox cradle in place like that when the engine is out?
 
Bob Z. said:
What do you use to keep the gearbox cradle in place like that when the engine is out?
Click to expand...
It's sitting on the bike jack still. After that, I use a piece of coathangar wire between one of the cradle bolt holes and a front mount hole.
 
Scroungy bottom end before clean-up

Decent trade for Purple Combat


Clean bottom end (heavily flushed inside as well)

Decent trade for Purple Combat


Tranny before clean-up

Decent trade for Purple Combat


Clean tranny (flushed inside as well)

Decent trade for Purple Combat


Filthy inner primary case half

Decent trade for Purple Combat


Inner primary cleaned up, not yet detailed.

Decent trade for Purple Combat


Kinda rare situation, chaincase is completely intact, no cracks at the 3 crankcase bolt holes or center boss, and the chain fling lip is completely intact.
 
Tranny back in it's cradle, re-assembly has begun.

Decent trade for Purple Combat


Lower end bolted in with original isolastics (in fair shape)

Decent trade for Purple Combat
 
Sprocket is SLIGHTLY hooked, but not terrible.

Decent trade for Purple Combat


New primary inner case gasket in place, ready to assemble primary system.

Decent trade for Purple Combat


Nice clean clutch plates; friction plates are $ureflex, steel plates are cleaned and lightly scuffed, pressure plate cleaned.

Decent trade for Purple Combat
 
Step 1 in proper assembly of primary is to gently snug the 3 inner bolts in place first...

Decent trade for Purple Combat


Step 2: measure gap between case backside and the shoulder of the stand-off stud.

Decent trade for Purple Combat


Step 3: Locate proper washers. One thick washer, one thin; just right.

Decent trade for Purple Combat


Step 4: Remove 3 inner bolts, slip in the proper washers, then tighten everything in place properly. Done.

Decent trade for Purple Combat
 
Primary system all shimmed in place, clutch plates & diaphragm spring installed, alternator cleaned & installed. Ready to nip it all up.

Decent trade for Purple Combat


I found 2 of the 3 inspection caps, and a proper sleeve nut for the center stud. Just need the 3rd cap & main cover o-ring.

Decent trade for Purple Combat


Tires are shot, as seen in this close-up (although they are still holding air). New filter has been knocking around my shelves for over a year, finally got a place to put it.

Decent trade for Purple Combat


Here and there, I always end up using my serviceable spares from lot purchases over the years. Almost like it's free. So far, well over a couple hundred dollars of old dusty parts that are now cleaned up and soon to be back on the road.
 
Battery tray all cleaned up and spray painted.

Decent trade for Purple Combat


Horn was HEAVILY caked with dirt and grime; cleaned up and painted. Mud dauber nest removed from inside, too...

Decent trade for Purple Combat


Oil tank solvent washed, then pressure washed, then spray painted.

Decent trade for Purple Combat


Man, this 100-plus-degree heat is beating me up. Even with my 36" Port-A-Cool parked 4' from my work are, and a 24" Shop Cool fan posted at my parts wash sink, I've been drenched in sweat for almost 6 hours. I tend to lose between 10 and 15 pounds every summer.
 
Oil tank installed, tore the only half-decent rubber isolator I had, so I made up an isolator from a long bolt and short section of rubber hose. Forget the runny paint, it's not a restoration.

Decent trade for Purple Combat


Oil line connections all done. Also plugged off the "factory oil leak" with a short section of hose & a thick allen screw with RTV silicone.

Decent trade for Purple Combat
 
Battery tray installed, as well as hidden horn (what a pain in the butt)

Decent trade for Purple Combat


Rear fender was caked with crud.

Decent trade for Purple Combat


Rear fender spiffed up and installed.

Decent trade for Purple Combat
 
Tail light all cleaned up, back plates painted, and installed. Painted the yokes and cleaned up the forks, will re-install them tomorrow.

Decent trade for Purple Combat


Sourced a serviceable set of cylinders, they are on the way to arrive in 2 days. Should be going back together with the top end by the weekend.
 
Forks flushed, cleaned & filled w/ 5oz 10W30 each, yokes painted, headlight ears polished up, meters & cups cleaned up, and all of that installed.

Decent trade for Purple Combat


Brake disc wire wheeled and the center painted, fender polished and stays painted, those items installed. Note the imperfect factory grinding, typical.

Decent trade for Purple Combat


Looking more like a bike, and it's back to a roller.

Decent trade for Purple Combat


Managed over 6 hours today with 2 breaks, I think we hit 105F...
 
Back
Top