So, I had a bit of time to fiddle with the bike this weekend, and thought I'd share my progress...
More head games. Rented a valve spring compressor...they didn't have the big C type, just the little one you can get at Harbor Freight for like $20. It's really designed to let you change the valve stem seals without pulling the head...which isn't what I'm dealing with here. Oh well, it's all they had.
Did it work? Mostly. It's really designed for longer springs in cars, and so I knew as soon as I hooked it up that getting the hooks down low enough was going to be an issue. I was able to use it to compress the spring, but then I had to push the tool down pretty hard to expose the keepers...and I used a magnet tool to snag them before i had to let the tool back up. I was able to get everything apart...it would be a real bear to reassemble with though. I'm gong to try and find the C style when they go back together.
So, what did the head look like? Pretty gross
It looks like the guy stored his bike in the river or something.
I could see that junk through the ports, so I knew it was pretty gooey, but I didn't realize it was that bad. I hit it with carb cleaner and a toothbrush first, and then gave it a bath in the ultrasonic machine for a couple of hours.
In the end, it came out about as clean as it can get without media blasting everything...it actually looks pretty good.
Ports are clean, guides are tight. I'm putting in new stem seals as well. Spent probably close to an hour and a half lapping the valves...really glad I got both coarse and fine compound...they needed it
. Seats cleaned up fine, and the valves are fine (no pitting or anything). So far so good...I'm really surprised the valves sealed at all before, but they didn't leak when I filled the combustion chambers...they should be good to go now. Just waiting on my new stem seals, and gaskets to toss the head back on. I'm going to use the cam and rockers off the original head.
I also discovered one small problem...
Yea, the seller didn't mention this one either :/
Not sure if this was freight damage or not, but I can't blame the seller for not noticing if it was there before...I've spent how many hours with this thing, and I just noticed...
I'll flatten the mating surface, and then I guess I have a few different options--
--Just try and tap the hole. The odds of hitting the threads right aren't very good, so this might just make a mess of it.
--Drill down 1/4" or so to remove the smoosheed threads...then the screw can grab the remainder of the threads down below that weren't damaged.
--Drill for the next size up and re-thread.
The last option is probably the best...the boss has plenty of meat to support the next size up, and that would give the bolt the full length of the threads to grab. Kind of an irritating situation, but I've got way too much labor in this thing to bag it over something like this lol. After I get this done, I'll give it one more ultrasonic bath to make sure there's no valve compound left, or any bits of aluminum from fixing this.
Also pulled the exhaust...I tried every way I could think of to get it out in one piece, but it wasn't going to happen. The bike is too low to the ground to get the cherry picker under it from the side, and too long to get the hook over the center of the bike
. So, I ended up dropping the pipes, and cutting through the crossover with a sawzall. I cut it at a spot where I could put another coupler in...if I can't find one that fits, I can probably fab one from another piece of muffler pipe. I could also just remove the crossover entirely, and just weld caps over the holes, but I would like to keep it there. It shouldn't be a big deal to make it work. I tipped the right side pipe up, and guess what fell out
Yep...well, at least I don't have to buy one
Pipes are really solid thanks to the low mileage...here's the left pipe before cleanup.
And here's the right pipe after cleanup...looks darn near new. The left pipe isn't quite as nice, but it'll look fine. It's going to be a rider, not a show queen
. All the rust and crud came off with some 4 aught steel wool. Also used some Eagle 1 polishing wool in spots.
They'll look really nice back on the bike. Thinking about hitting the bare metal parts with some black header paint before I put it back together to give it a little more rust protection. It was really nice cleaning the pipes off the bike...sooo much easier to get everything that way.
Was also originally going to replace the right side valve cover since it hit the pavement, but I think I'm going to try and salvage it. It's not cracked, and I think I can make it look pretty nice...I have a lot of experience in metal finishing, and I think it'll turn out ok. It won't be perfect just because it does have some damage, but it'll look nice. There are a ton of these on ebay, but none of them are any better than what I've got, unless you want to pay a hundred bucks for them. And I don't want to pay a hundred bucks lol.
Here's what I'm starting with.
I'll post an "after" when it's done.
Oh, and I also got the ignition switch back in...the PO removed it to get a key cut because the estate didn't have one. Getting those screws in was...interesting. It was dark, and I could't get the drop light positioned to where I could actually see what I was doing. Eventually got them in anyway. Won't have to do that again soon anyway...
Also finished cleaning up the #1 cylinder...it has some light pitting at the top of it that couldn't be cleaned up without boring it
. Oh well. I'm just going to run it...it would require a complete teardown of the engine to fix it "right", and since the rest of the motor should be very solid for a million more miles, I'm going to worry about it at some future point. It's at the very top, so it may be above where the oil control ring stops anyway, so it may not even be an issue. I guess we'll see.
She's getting there
. Carb kit should be here in the next few days, and that will be the next adventure... Head gasket stuff should be here this week too. Who knows, I might be able to get a test fire out of the engine in the next couple of weeks