my conversion thread.
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Tourer
Joined: Jul 2008
Posts: 300
Likes: 4
From: Boise, Idaho
I've made a little progress the last couple days, but not much. Too much work.
I got the cam cover sprocket cover, rocker box covers, rocker boxes, and the heads off.
I had really planned to go into details of how all this stuff comes apart, but there is another thread right now that already has it all covered. I have been reading that one to help me along. Much thanks to Mich for that.
It really hasn't been difficult at all. Anyone with a shop manual and some tools can do the tear down. I'll see about the re-assembly. That might be a different story.
I talked to the paint guy today. He is picking up the parts on Wednesday. All the covers are going to be a really deep gloss black. I decided to go with red on the rocker boxes. That should look good with my red sparkplug wires and the red on my tank. He is also going to paint my heads black to match the cylinders.
Hopefully tomorrow I will get the 1250 kit on. I'ts gonna kill me to wait for paint.
I got the cam cover sprocket cover, rocker box covers, rocker boxes, and the heads off.
I had really planned to go into details of how all this stuff comes apart, but there is another thread right now that already has it all covered. I have been reading that one to help me along. Much thanks to Mich for that.
It really hasn't been difficult at all. Anyone with a shop manual and some tools can do the tear down. I'll see about the re-assembly. That might be a different story.
I talked to the paint guy today. He is picking up the parts on Wednesday. All the covers are going to be a really deep gloss black. I decided to go with red on the rocker boxes. That should look good with my red sparkplug wires and the red on my tank. He is also going to paint my heads black to match the cylinders.
Hopefully tomorrow I will get the 1250 kit on. I'ts gonna kill me to wait for paint.
Thread Starter
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Tourer
Joined: Jul 2008
Posts: 300
Likes: 4
From: Boise, Idaho
I finished the disassembly today. Everything came right off. I was a little worried about getting the lock rings off of the piston pin, but it was no problem. One of the cylinder studs had some rust on the bottom. I'm not sure what caused it, but it cleaned up pretty well.
I used some carb cleaner to get the surfaces cleaned up, and then installed the new cylinders and pistons. NHRS had assembled my pistons and put them in the cylinders for me, so I didn't have to worry about gapping. Everything lined up well for the re-install but the cylinders didn't seat as well as I had hoped. I need a solid thunk to tell me all is well, and that just didn't happen. It was a lot of wiggling and adjusting to make them slide down the studs. At the bottom, the new metal gasket just does not make for a solid feel either.
This was the only place I have had help too, and that always makes me wonder. I tend to hurry through things when I have help. I hate to tie someone up on a Saturday to work on my projects.
So now I mostly have to wait for the paint. Its gonna be rough. I am taking the kids to Disneyland on the 19th, and I bet the paint isn't done yet, so I won't get back into it until almost March. That is a long time for a project to sit idle. I might have to come up with something else
I used some carb cleaner to get the surfaces cleaned up, and then installed the new cylinders and pistons. NHRS had assembled my pistons and put them in the cylinders for me, so I didn't have to worry about gapping. Everything lined up well for the re-install but the cylinders didn't seat as well as I had hoped. I need a solid thunk to tell me all is well, and that just didn't happen. It was a lot of wiggling and adjusting to make them slide down the studs. At the bottom, the new metal gasket just does not make for a solid feel either.
This was the only place I have had help too, and that always makes me wonder. I tend to hurry through things when I have help. I hate to tie someone up on a Saturday to work on my projects.
So now I mostly have to wait for the paint. Its gonna be rough. I am taking the kids to Disneyland on the 19th, and I bet the paint isn't done yet, so I won't get back into it until almost March. That is a long time for a project to sit idle. I might have to come up with something else
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Tourer
Joined: Jul 2008
Posts: 300
Likes: 4
From: Boise, Idaho
I kinda forgot that I was documenting my project, so not many pictures of the reassembly. Everything went according to plan, except I didn't get one pushrod cover o-ring seated well, so I had to tear a head back off. Things are good now though. No oil leaks, and all is running.
Thanks to Dan from NRHS for diagnosing the oil leak. I have about 120 miles on the new engine so far. There is no way I will be able to keep below 3200 rpm for 350 more miles. There is significant more fun in the low rpm range. I can't wait to turn the throttle a little bit.
The Engine kit part of this project can easily be accomplished in a weekend by anyone with some tools and the ability follow directions. The paint took a long time, and if I were to do it again, I think I would spend the money and go with powder coat.
The forks are going to have to go black, but I am out of project money for a while. I am happy with the new look. I thought I would end up painting the engine block, but for right now I kinda like the contrast.
Here is the finished product.
Thanks to Dan from NRHS for diagnosing the oil leak. I have about 120 miles on the new engine so far. There is no way I will be able to keep below 3200 rpm for 350 more miles. There is significant more fun in the low rpm range. I can't wait to turn the throttle a little bit.
The Engine kit part of this project can easily be accomplished in a weekend by anyone with some tools and the ability follow directions. The paint took a long time, and if I were to do it again, I think I would spend the money and go with powder coat.
The forks are going to have to go black, but I am out of project money for a while. I am happy with the new look. I thought I would end up painting the engine block, but for right now I kinda like the contrast.
Here is the finished product.
Road Master
Joined: Aug 2011
Posts: 858
Likes: 17
From: victoria bc
Bike looks great. the red is really unique.
was one of the upper o rings pinched on your pushrod tube?
You can do the break in period. It was damn hard but once it's over hold on! I had 2 great tuning runs yesterday. I was really able to open it up and when I got home and modified my map the bike is running alot smoother.
Keep us updated on how it works out for you.
was one of the upper o rings pinched on your pushrod tube?
You can do the break in period. It was damn hard but once it's over hold on! I had 2 great tuning runs yesterday. I was really able to open it up and when I got home and modified my map the bike is running alot smoother.
Keep us updated on how it works out for you.
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Tourer
Joined: Jul 2008
Posts: 300
Likes: 4
From: Boise, Idaho
Thanks. I'm really digging the red.
It was a pinched lower o-ring. I didn't get it seated right when I swapped them out. The only other problem I ran into was I broke one of the bolts inside the rocker box. My torque wrench was set at 145 in-lb and it didn't make it.
It was a pinched lower o-ring. I didn't get it seated right when I swapped them out. The only other problem I ran into was I broke one of the bolts inside the rocker box. My torque wrench was set at 145 in-lb and it didn't make it.
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