Timberwolf
06-23-2007, 01:28 AM
had a torn cam cover seal and when he pulled the cover, the cam slid out far enough for the lifter rollers to drop off the side of the the lobes. Got lucky and was able to reset it by just loosening the adjustable pushrods (counting the turns) to take the pressure off the lifters and never even had to take a valve cover off.
But then we didn't realize the gear that drives the crankcase vent aperture had to be timed with the crank and cam gear, so when we fired it up, it was scooping oil and sending it out the vent tube. Made a nice mess :)
Got the gear retimed and everything put together, and the bike wouldn't fire. Pulled it back down and found the rotor wasn't engaging the end of the cam. The roll pin that held it into the notch had sheared off. What we didn't notice was that the pin came in from the side of the rotor, and when we saw the hole in the bottom (with an alignment pin sticking out the other side for indexing the magnetic pickup trigger), we assumed that's where it broke off. Put a new pin in that hole and reassembled. Still wouldn't run unless I cranked the ignition WAY retarded. Knew that couldn't be right, so tore it back down and discovered the CORRECT hole for the pin :)
Got that figured out and noticed the primary chain drive was loose, so we pulled the inspection cover and adjusted that... wondered why there was a lot of silicon under there, but didn't think much of it. Put a new gasket under the cover after cleaning it of all the rtv and buttoned it back up. Fired the bike and it was DUMPING oil (trans fluid actually) out of the inspection cover. Turns out the guy that freshened it last winter had bent the cover or installed one that wasn't machined correctly... thus the silicone. I put a straight edge across it and found it was a good .050 out in the center. Lapped it for 45 minutes to get it flat enough to seal. No more leaks there, and no silicone!
Luckily he has a bike lift in the garage to make it MUCH easier to work on!
Finally got it all sealed, running great, and leak free, so we polished it up and I shot a couple pictures. Sorry they are so big. I didn't bother resizing because I figured the board would :) if you want to see them as resized by your favorite browser, the index is here: http://www.sixtyninecamaro.com/images/harley/
But then we didn't realize the gear that drives the crankcase vent aperture had to be timed with the crank and cam gear, so when we fired it up, it was scooping oil and sending it out the vent tube. Made a nice mess :)
Got the gear retimed and everything put together, and the bike wouldn't fire. Pulled it back down and found the rotor wasn't engaging the end of the cam. The roll pin that held it into the notch had sheared off. What we didn't notice was that the pin came in from the side of the rotor, and when we saw the hole in the bottom (with an alignment pin sticking out the other side for indexing the magnetic pickup trigger), we assumed that's where it broke off. Put a new pin in that hole and reassembled. Still wouldn't run unless I cranked the ignition WAY retarded. Knew that couldn't be right, so tore it back down and discovered the CORRECT hole for the pin :)
Got that figured out and noticed the primary chain drive was loose, so we pulled the inspection cover and adjusted that... wondered why there was a lot of silicon under there, but didn't think much of it. Put a new gasket under the cover after cleaning it of all the rtv and buttoned it back up. Fired the bike and it was DUMPING oil (trans fluid actually) out of the inspection cover. Turns out the guy that freshened it last winter had bent the cover or installed one that wasn't machined correctly... thus the silicone. I put a straight edge across it and found it was a good .050 out in the center. Lapped it for 45 minutes to get it flat enough to seal. No more leaks there, and no silicone!
Luckily he has a bike lift in the garage to make it MUCH easier to work on!
Finally got it all sealed, running great, and leak free, so we polished it up and I shot a couple pictures. Sorry they are so big. I didn't bother resizing because I figured the board would :) if you want to see them as resized by your favorite browser, the index is here: http://www.sixtyninecamaro.com/images/harley/