11/18/04

All break down and inspection work has been completed. Look below for details.

notes:

• old cylinder was pitted and would not clean up acceptably on the boring bar - still had to pay block shop $75
• new cylinder obtained today from Hugh at 6th St. Specials for $50
• checked new cylinder with bore guage - OK - .0005 variance TIR both bores - .040 oversize pistons will be fit at .005 loose
• cylinder still requires deck checking, tappet block installation, painting
• case prep completed - ready for assembly
• crank is back from machine shop and looks great - shell bearings obtained for -.010 journals - still requires thorough cleaning to remove any remaining lapping/grinding compound (I'm not going to take their word for it)
• all lower end covers have been glass beaded, blasted with walnut hulls, then soaked in boiling soapy water - all ready for reassembly
• all bearings ordered today: sprocket shaft w/race, pinion shaft, left and right side mainshaft, right and left layshaft. These were not available at local power transmission shop as they are specialty items. Normal motorcycle distributor prices apply.
• all gaskets and oil seals ordered today
• removed valve guides from head - blasted all carbon from port-side protrusion, heated casting around guide to 300F, used precision drift with pilot through guide. Holes look good and are not broached. One guide was signifigantly (and incorrectly) oversized. Measured valve guide bores for new guides. Will order tomorrow.
• head casting is a little odd - one valve seat seems to be offset such that it will be difficult to get the valve to seat correctly - will consult head shop and report back
• ordered new con rod nuts - these nuts are of the deformed-thread lock nut variety and should not be re-used.
• considering using existing cams as pitting is only on one cam and is on the egress side of lobe away from high-lift area.

Here are some pics: