Need my head examined (beware monster pics)

[Guest]

the dowel I improvised is just plain gone. I didn't take it out of the head, but it's not in the head or cylinder block. It's not in the pile of oil absorbent stuff on the floor. It's not in the bin of parts I took off the bike. ... I took off the old oval o-rings before I stuffed rags down alongside the pistons. Sure enough, I fumbled one right past a piston, and it's not on top of the crank. Pretty sure that gasket kit came with an oil pan gasket... Hopefully both surfaces are accessible to the Ruloc wheel.

It's gonna be mighty close.

Loose o-ring, not good but not the end of the world, missing metal part will need you to be absolutely sure it's not hiding on the inside when you button it up. Remember, everything inside shares the oil bath, so consider the damage if it is hiding in there somewhere.

We pulled Coles starter clutch tonight on the GK...totally destroyed. Also found out that the GK used a different set up than ... Small end 1100E Rotor, starter clutch and flywheel. ID and OD of the bearings, and all essential contact points on the crank snout are exactly the same, as is the diameter of everything else. This SHOULD work just fine. We hope.....

Best case is a bump start if it should just fail to work on the trip, worse case... I don't wantto think about that...

It's supposed to rain all damn day so I don't know if you'll get much ride test time in before tomorrow. If things go wrong on your guys trip down to the meeting place remember to call me as I'll have my cell linked. We'll leave you a message if something goes bad for us too.

Speaking of rain... looks like we will be chasing this front across the state into WV tomorrow. I expect wet roads if not some leftover showers possibly. The weather liar says it's going to be mostly cloudy with the temps on the cooler side. Packing rain gear for me might mean less tools packed.

 

[Dogma]

Jim, I don't think I'd let even the o-ring stay in there. The dowel... I don't see how it could have not been in either the head or the block.

Expect a call later this evening. I'm still sketchy on the morning's plans, including just exactly when and where we plan to meet to launch out of the Cincinnati area.

 

[Calvin Blackmore]

Jim, I don't think I'd let even the o-ring stay in there. The dowel... I don't see how it could have not been in either the head or the block.

Expect a call later this evening. I'm still sketchy on the morning's plans, including just exactly when and where we plan to meet to launch out of the Cincinnati area.

have you searched the garage floor
it may have stuck in the head and then dropped out when you pulled it off
maybe while carrying the head to abench......

 

[Dogma]

have you searched the garage floor
it may have stuck in the head and then dropped out when you pulled it off
maybe while carrying the head to abench......

Yep. It's shouldn't have been loose, though. It's a strip of aluminum I wrapped around a screwdriver. It's bigger than the hole, so it had a spring/press fit. It should have stayed in one side or the other. I haven't looked into the numbers, but maybe the head gets hot enough to stress-relieve that thin scrap of aluminum so it's not tight anymore. I'm pretty sure I put it in there... I'll have another look in the empty spaces in the block this afternoon, while I have better light.

Anyhow, I know that o-ring is in the engine somewhere. So, while I'm finding that, I'll also make real sure that dowel isn't in there too.

 

[TheCafeKid]

Loose o-ring, not good but not the end of the world, missing metal part will need you to be absolutely sure it's not hiding on the inside when you button it up. Remember, everything inside shares the oil bath, so consider the damage if it is hiding in there somewhere.



Best case is a bump start if it should just fail to work on the trip, worse case... I don't wantto think about that...

It's supposed to rain all damn day so I don't know if you'll get much ride test time in before tomorrow. If things go wrong on your guys trip down to the meeting place remember to call me as I'll have my cell linked. We'll leave you a message if something goes bad for us too.

Speaking of rain... looks like we will be chasing this front across the state into WV tomorrow. I expect wet roads if not some leftover showers possibly. The weather liar says it's going to be mostly cloudy with the temps on the cooler side. Packing rain gear for me might mean less tools packed.

Trust me, between Cole and I, both having learned our lessons at RRR, neither of us comes without every single possible tool you could need to work on a bike short of breaking down the top end. (I dont foresee us pulling any wristpins on the side of the road.) So we got you covered Jimmy, even with that new fangled bike of yours. I Dunno how that big GK's been starting. I dunno how long this clutch had been like this, but it looked like it was a start or two away from literally exploding. I will try to post up some pics for everyones enjoyment later. I feel good about this fix working just fine, and provided it goes as planned, it will take me longer to scrape gasket off the stator cover than get the parts in and bolted up. So no worries there. I have a list of stuff to do today that if wadded up could choke a blue whale, so wish me luck. Dale, i hope you manage to get your bike going! Call me if you have any questions, but since you've done it once, im sure you're probably grasping it well now.

 

[Dogma]

Just taking a dinner break. What a great day to be in the garage!

Cahllenge! Guess everything that's in the oil pan! That washer may be a challenge to some. I had to go check to make sure it wasn't somehow my fault that such a thing was in the pan. Is anything more vile than a PO?

Seriously, what's with all the metal in there? It's been a long time since I ground the gears...

OK, back to work.

 

[bwringer]

EEwwww!

Notice how that o-ring is swollen -- it's a lot bigger than it should be. That's how mine failed.

The washer is from the starter gear, of course -- that actually happens a lot.

I've never seen that much gunk in the pan, though. What on earth happened to that poor bike?

Wish I had thought to toss in a few of those dowel pins for ya.

 

[TheCafeKid]

Well, Fingers crossed for ya Dale, i hope it stays oil tight. Or at least MOSTLY oil tight. Got Cole's GK squared away. Buttoning that back up as we speak. Things have gone amazingly smooth today. Tooooo smooth. Something bad is bound to happen...

 

[Dogma]

After leaving that o-ring on the floor for a few hours, it didn't seem much larger than the originals I had taken out. I didn't compare them side-by-side though.

There's a washer that look like that on the starter gear? I thought is was the back half of the clutch throwout bearing. It looks exactly like mine.

 

[Dogma]

Well, Fingers crossed for ya Dale, i hope it stays oil tight. Or at least MOSTLY oil tight. Got Cole's GK squared away. Buttoning that back up as we speak. Things have gone amazingly smooth today. Tooooo smooth. Something bad is bound to happen...

Gotcha covered. I finally got it back together about 3:40 last night. It wasn't responding to the throttle the way I'm used to, but I figured the bowls hadn't filled yet. I was feeling pretty loopy, so I took a shower went to bed. Up at 6:09 (one snooze), put the gear on and headed out. No power past 1/4 throttle or about 3500 rpm. Otherwise smooth and sounds a little funny. It looks like I somehow managed to screw up the cam timing again.

 

[Dogma]

Gotcha covered. I finally got it back together about 3:40 last night. It wasn't responding to the throttle the way I'm used to, but I figured the bowls hadn't filled yet. I was feeling pretty loopy, so I took a shower went to bed. Up at 6:09 (one snooze), put the gear on and headed out. No power past 1/4 throttle or about 3500 rpm. Otherwise smooth and sounds a little funny. It looks like I somehow managed to screw up the cam timing again.

Just to wrap this thread up: Fixed the timing, and all was well for the 1300 or so miles at the WV rally. Thanks ot everyone for the help.

 

[xDownSetx]

Glad you got everything wrapped up just in time, was a fun read. Hope you had a blast at the rally. You earned it!

 

[DimitriT]

Reinstall head and spray water into the intake

Too much trouble ? OK get the wallnut shells out

Does the water thing actually work? Has anyone seen before and after kind of comparison?

 

[xDownSetx]

I've heard that soaking carbon in a little bit of antifreeze will make it come right off. I haven't had a chance to try it yet though.