1986 Aspencade Resurrection

[3KidsinAustin]

Sometimes just need brushes as well. And they are cheap

You are right. Minimum spec is around 5.5mm - the brushes in my starter were around 10mm, so I just cleaned them all up.

[CYBORG]

[3KidsinAustin]

Unseasonably cool, overcast weather this morning, so a great time to get out and clean up the rear rim. Went after it with some medium grade steel wool and worked it pretty hard. Picture shows the difference between before and after.

2025-06-10 10.44.47.jpg

To remount the tires, I used a set of 48" zip ties. Doing this eases installation greatly as you only after to work the tire over the rim once - I'm a big fan. By the time I got to this point, the sun had popped back out, so I left the tire in the sun for a couple of hours, zip tied it, then rubbed the bead and the rim with soapy water.

2025-06-10 13.19.27.jpg

I tried to get fancy with some QuickJack blocks to keep the wheel elevated, but it kept falling off when I tried to work the tire over the edge of the rim. After laying it directly on the cardboard I was able to work the tire over in sections, not too bad.

2025-06-10 13.29.19.jpg

Next, the part I'd been dreading. Filled it up with air and checked for leaks after bouncing the inflated tire around. One side was perfect, the next had the slightest of leaks in two areas. Crushed, I went inside and pondered the meaning of life for awhile. After a spell, I proceeded outside, took my rubber mallet and proceeded to whack the bejeezus out of the areas where it was foaming. First, I hit the tire around the rim (not actually hitting the aluminum, just the rubber), then after a few sessions I really went after the larger tread area. After three or four beatings, the wheel must have decided resistance was futile and the leaks have stopped. For now... I've celebrated before, so I'm holding off for awhile before claiming victory. Regardless, here is the tire as it now sits, temporarily bested by an angry guy with a BFG.

2025-06-10 16.13.55.jpg

[Fred Camper]

Just wow, now I know why I go to a tire shop.

[3KidsinAustin]

Just wow, now I know why I go to a tire shop.

I agree! None near me or that would be my first stop. I think my next trip to Autozone, I'll pick up some tire bead sealer as I need to replace both tires on the upcoming 84 project. I had zero trouble on the front tire that I replaced on the 85 but this one beat the band.

[3KidsinAustin]

The good news is that I have found incontrovertible evidence of the cause of my oil leak. The bad news is the left head needs to come off, again. This is the one I removed earlier to play with the valves. There is a section of head gasket completely missing down in the oil return area. I was watching it on my back while the bike was running and with a flashlight pointed in the area. I could shine light through the opening and confirmed it by sticking a feeler gauge through the joint.

2025-06-11 15.11.47.jpg

Looks like a project for tomorrow. Drain coolant, drop radiator, remove exhaust, intake runners, alternator and pulley, set timing, remove belt and cam pulley and THEN the head can be pulled. I'll be interested to see the gasket - will certainly be plenty careful putting the second one on!

[3KidsinAustin]

I wish to humbly thank this motorcycle for giving me so many opportunities to succeed, despite my best efforts. Today was spent going through the process of removing the cylinder head to change the gasket and reinstall. As I mentioned yesterday, there was an area in the head where there was no gasket sealing it to the block. Avid readers might recall I attributed this to a damaged head gasket.

Your Honor, I submit the picture below as evidence against the moron currently sitting in front of the keyboard...

2025-06-12 11.56.02.jpg

Yep, I installed the gasket backwards. For readers that have not had the privilege of digging into the upper half of the engine, the proper orientation of the gasket is as follows:

2025-06-12 12.00.24.jpg

I managed to leave a sizeable portion of the drain cavity exposed. Oops.

All is reinstalled and working properly. Still a bit of oil on the exhaust headers that is burning off but no leaks identified yet.

Waiting on an oil seal for the leaking rear shock absorber then the bike can be reassembled and road tested again. So far no air leaks on the rear tire.

[Fred Camper]

Good news on the rear tire, that was one big learning event.

[3KidsinAustin]

Good news on the rear tire, that was one big learning event.

Been a couple of days and still holding air, so I mounted it back under the bike. Had to deflate it to 20psi then reinflated, so I think I'll do another soap test just to be 100% certain.

With the rear suspension off, the old gal really takes on the "slammed" look.

2025-06-13 15.28.36.jpg

[3KidsinAustin]

Took longer than I expected and looked like a slasher-movie aftermath with ATF everywhere, but I got the oil seal replaced in the leaking rear shock. Everything is starting to go back onto the bike but the heat was getting to be too much after the couple of hours I was out there putting the suspension back together. Hopefully get some test rides on it soon!

2025-06-16 12.24.50.jpg

[Fred Camper]

Good news but sorry about the heat. Mornings are your friend for a while.

[3KidsinAustin]

Mornings are your friend for a while.

My friend, you speak the truth! Took it for a test ride earlier and had ups and downs. The oil seal on the rear shock is doing its job, so that's a plus. Downside is the speedo fix I posted a few up was again non-functional. Fortunately, I had one last chip to solder back in. This time I left out the silicone and running it dry. If it holds up, I'll probably look at some proper potting material. Also had a leak from the upper radiator hose (I hope that is where it's from). Had to pull out the alternator to get a good grip on the band clamp and really gave it the business with some serious tightening. Felt like a little moisture coming off the right side as well, might be from the overflow tube. I'm riding with the tank shelter off just so I can try and spot these little things.

Daughter itching for a ride on the back, so I through the bags back on to keep her in a more confined space. Will surprise her with a ride after her swim team lessons in the morning.

[gltriker]

snip
Also had a leak from the upper radiator hose (I hope that is where it's from). Had to pull out the alternator to get a good grip on the band clamp and really gave it the business with some serious tightening.

If the radiator hose and hose connection surfaces are clean and intact, these "hose clamps" are quite likely the solution
viewtopic.php?p=814021#p814021

I don't know whether those pictured "hose clamps" are the same size the 1986 Aspencade would require, though.
Scroll down this size selector chart
https://www.gates.com/us/en/fluid-power ... 00000.html