[garrettL]

I hope this is in the right "sub-forum"
I traded for this bike awhile ago. I had a lot of "to dos" when I moved out to my parents for a new career so with that settled I can finally start a build thread.
The head was toast after inspection. Got quotes from ED for rebuild and now I'm finally getting into tearing it apart.
I'll post more pics as I progress.

Picked up an owners manual on Ebay for super cheap, and I have the supplement coming from Ebay as well.

This is one of the most informative forums I have ever found, if not the best. Thanks again everyone past and present for the info you share to us greenies.

 

[Tom Schmitz]

That cat is very close to being Dark Ghost Gray Fed Std 595C 36320.

Izzat a military cat? Navy, maybe?


Looking forward to your thread!

 

[Br549rick]

i like the "guard cat"

 

[banditcilik]

That is a soft box

 

[garrettL]

That cat is very close to being Dark Ghost Gray Fed Std 595C 36320.

Izzat a military cat? Navy, maybe?


Looking forward to your thread!

I had to look that color up, she does really match that color!! I didn't even realize she was in the picture until after

 

[garrettL]

I got carried away organizing and redoing the garage lighting/shelving. I can actually have a place to work on the bike now. Heres a good front end pic

I drained the oil and removed the filter. The filter has shards embedded in it LOL
I wonder what the sharpie markings are from

While that was all draining, I removed the petcock to prepare to either find a brass plug for the vacuum nipple or make a plate from aluminum I have in my garage

Tomorrow the head comes off and I can see what condition the jug/piston is in

 

[Fetona]

I hope this is in the right "sub-forum"
I traded for this bike awhile ago. I had a lot of "to dos" when I moved out to my parents for a new career so with that settled I can finally start a build thread.
The head was toast after inspection. Got quotes from ED for rebuild and now I'm finally getting into tearing it apart.
I'll post more pics as I progress.

View attachment 39712 View attachment 39713

Picked up an owners manual on Ebay for super cheap, and I have the supplement coming from Ebay as well.
View attachment 39714
View attachment 39716

This is one of the most informative forums I have ever found, if not the best. Thanks again everyone past and present for the info you share to us greenies.

Your cat is day dreaming!

 

[garrettL]

So today I got the head off, the carb is kind of a pain in the ass to remove while being careful not to break anything
(plastic vacuum/fuel nipples)

If you look closely you can see the idle jet/needle? was maxed out by the PO so wonder what was going on

Everything looks solid and clean, bike only has 11k miles. PO did the doohickey when we were negotiating trade, I think he would've rather sold it
I need to remember to check his work just so I'm confident in it

Head looked pretty nice other than the ruined cam journals

Cross hatching looks good to me, granted I don't have years of experience . Its weird that the pistons mark up the front and rear of the cylinder
If anyone can tell me a good way to measure the piston to cylinder clearance? I would prefer to not have to remove the jug and save some money on 685.

Heres all the stuff I took off so far, I did end up finding a hex block off plug for the petcock so I'll get pics next time

Tomorrow I have work but I'd like to get the right side cover off and clean that "screen" and do a general inspect

Do you guys have any ideas for flushing out the engine of the debris from the head? I was thinking just filling up a garden spray bottle with diesel and rinsing everything
thanks for looking!

 

[banditcilik]

My concern is the garden spray bottle won't flush the metal debris in the oil orifices

 

[garrettL]

My concern is the garden spray bottle won't flush the metal debris in the oil orifices

That was my thinking too, maybe I can take a syringe and squirt it in the oil filter clean oil hole

 

[garrettL]

Finished removing the inner case and doohickey so I can properly flush the case

The oil screen is soo much smaller than I originally thought

This is the plug that I was talking about earlier, I'm thinking some gasohol sealant and it should work great

 

[banditcilik]

Wow look at all that metal crap

 

[garrettL]

Wow look at all that metal crap

Heres the inside of it

 

[Six8five]

The reason your engine was oil starved was from over consumption.
It would be foolish to not replace the rings and piston and get a fresh bore.
The engine will continue to consume oil and it will be a pain in the ass to keep it full of oil.
You have went this far no need to half ass it now.

 

[garrettL]

The reason your engine was oil starved was from over consumption.
It would be foolish to not replace the rings and piston and get a fresh bore.
The engine will continue to consume oil and it will be a pain in the ass to keep it full of oil.
You have went this far no need to half ass it now.

Its obvious it was starved of oil but " over consumption" is pretty vague and from all the research and looking on here it seems the gen 1 pistons and rings really didn't have issues. SO I'll have to keep looking. 4-500 $ is a lot to put into something that could be perfectly usable.

 

[Six8five]

Its obvious it was starved of oil but " over consumption" is pretty vague and from all the research and looking on here it seems the gen 1 pistons and rings really didn't have issues. SO I'll have to keep looking. 4-500 $ is a lot to put into something that could be perfectly usable.

That’s exactly what my piston and cylinder looked like and mine burned a lot of oil.
If it wasn’t the the rings that allowed the high consumption then what do you think it was?

 

[garrettL]

I don’t know exactly

That’s exactly what my piston and cylinder looked like and mine burned a lot of oil.
If it wasn’t the the rings that allowed the high consumption then what do you think it was?

I don’t know exactly but my only idea would be that he liked to keep it at high rpm all the time and was too ignorant to check the oil. Then it slowly starved the head

 

[Six8five]

That is plausible
I’m not trying to bust your balls it’s just a lot easier to do it now.
I would want that piston gone due to the fact that it only has 3 tiny holes on 2 sides below the oil scraper for drain back, terrible design.
A new forged piston has lots of large holes and weighs much less making a smoother engine.

 

[garrettL]

That is plausible
I’m not trying to bust your balls it’s just a lot easier to do it now.
I would want that piston gone due to the fact that it only has 3 tiny holes on 2 sides below the oil scraper for drain back, terrible design.
A new forged piston has lots of large holes and weighs much less making a smoother engine.

Oh you’re okay, I like feedback that’s why I posted it on here. Sometimes we get bullheaded I forgot about the oil hole issue, well I’ll have to see what a total cost would be and see if I can swing it.

 

[pdwestman]

The fork boots eventually need to be slid UP. Other wise the suspension can't use full stroke.
If you are converting to manual fuel valve there is no reason to plug the rear cap of fuel valve, but the brass carburetor nipple needs to be capped.

There is no way to measure piston to cylinder clearance on an assembled engine.
The piston could have had a hydo-lock event from a flooding carburetor with can break the ring land between top & second ring, creating an Instant massive oil consumer.
An EM 661 0r 685 kit is the best way to go.