"Parts Bike" a '77 rebuild thread

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Re: "Parts Bike" a '77 rebuild thread

#31

Post by Rat »

Now there’s a holiday ....

Gord :shock:
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Re: "Parts Bike" a '77 rebuild thread

#32

Post by robbie202 »

got the heads back.
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valve_a.jpg
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Re: "Parts Bike" a '77 rebuild thread

#33

Post by robbie202 »

robbies status update:
no meaningful progress on the 'wing since i last posted a little over a year ago besides putting it up on the stand. been cooped up with my three teenage boys while i was teaching elementary school virtually. at least i had the wee little kawasaki 250 to ride around town when necessary and i did a lot of work on the sportster out in the garage to satisfy my tinkering cravings and stay sane. so no news, just saying hi to the group. at the end of the month we will be off work for the summer and i'll get back into this project properly asap after that. can't believe this saga started 9 years ago lol.
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Re: "Parts Bike" a '77 rebuild thread

#34

Post by robbie202 »

updated the to do list on the whiteboard.
the "A" section is to get the motor running and the "B" section is everything else.
whiteboard.jpg
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today's job is the LH head gasket. first time doing this. HF stand has the skinny part on top but the solid safety bar. good so far.
HF_Stand.jpg
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Last edited by robbie202 on Sat Jun 12, 2021 7:18 pm, edited 1 time in total.
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Re: "Parts Bike" a '77 rebuild thread

#35

Post by robbie202 »

these are all of the seals and such that i am replacing.
the valve seals were done by the machine shop previously.
seals.jpg
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Re: "Parts Bike" a '77 rebuild thread

#36

Post by robbie202 »

so o-rings for the oil orifice part. place these locator dowel pin pieces.
make sure the gasket is on the right way. parts are stamped which way they go.
(picture was taken before i cleaned the old gasket material off the surface)
dowel.jpg
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gasket.jpg
gasket.jpg (100.8 KiB) Viewed 374 times
left_hand.jpg
left_hand.jpg (71.97 KiB) Viewed 374 times
seal.jpg
seal.jpg (107.98 KiB) Viewed 374 times
shape.jpg
shape.jpg (84.54 KiB) Viewed 374 times
Last edited by robbie202 on Sat Jun 12, 2021 7:40 pm, edited 1 time in total.
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Re: "Parts Bike" a '77 rebuild thread

#37

Post by robbie202 »

re-using the bolts and one of them snapped off. when i felt it go i definitely had a minor heart attack.
turned out not to be that bad. after i got that cam rocker part back off the broken tip of the bolt was sticking out far enough to grab it with the vice grips. i had it lubed with the moly grease and was using the torque wrench in increments with the cross pattern. must have been damaged by the previous owner. not surprised after seeing the lack of care that was taken with the valves and cams.
broken_bolt.jpg
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Re: "Parts Bike" a '77 rebuild thread

#38

Post by robbie202 »

valve cover is back on. all of those parts are refreshed so that should be it for the LH head.
we'll see if it holds lol. not going to polish the cover but i will restore the badges at some point.
valve_cover.jpg
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Re: "Parts Bike" a '77 rebuild thread

#39

Post by robbie202 »

looks like these gaskets are out of print. going to try some RTV or something to seal these later.
next step - the RH head (should be the exact same as this one) then i can do the belts and ignition module and address the fabrication of a cover where the mechanical fuel pump used to go.
need_rtv.jpg
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Re: "Parts Bike" a '77 rebuild thread

#40

Post by robbie202 »

Right side didn't go on without a fight
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Re: "Parts Bike" a '77 rebuild thread

#41

Post by robbie202 »

This arrow gave me anxiety the way it was pointing backwards i thought i had the wrong part but they are identical. Everything lined up.
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Re: "Parts Bike" a '77 rebuild thread

#42

Post by robbie202 »

The threads may have been previously damaged in this one bolt hole that had the stuck dowel. I didn't have the right tap to chase the threads. It got hard to turn towards the bottom but i don't think it was cross threaded. Hope that's a good seal because it might not go in again.
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Last edited by robbie202 on Sun Jun 20, 2021 7:40 am, edited 2 times in total.
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Re: "Parts Bike" a '77 rebuild thread

#43

Post by robbie202 »

Both heads on. Belts are next.
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Re: "Parts Bike" a '77 rebuild thread

#44

Post by Track T 2411 »

Just make sure you get the cam gears on the correct way. One side of each gear is marked 'R' and 'up' which should face the front of the bike on the right side cam as you sit on the bike. The 'R' faces the back of the bike on the left side cam.
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Re: "Parts Bike" a '77 rebuild thread

#45

Post by robbie202 »

Track T 2411 wrote: Wed Jun 16, 2021 8:06 pm Just make sure you get the cam gears on the correct way.
Exactly right. That's something i noticed is that some of the engine parts are identical but not symmetrical. Others are labeled LH or RH.
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