Fixing oil suckage in 2003 (project for a friend)

[mattrat]

head is about half reassembled. I'm takin a break.

[twotonevert]

I have very much enjoyed this thread. Props to you for helping your friend out.

[Jaegermeister]

I have very much enjoyed this thread. Props to you for helping your friend out.

Props is right! I can't wait to hear that you and your wife are rocketing around the Texas Hill Country with 200hp under you. You should scoot out to Lukenbach if it's ready this weekend.

[mattrat]

SHOOT...
one of the valve cotters is bent...
Work stopped for the smallest part in the whole bike.

[Jaegermeister]

So, if the shim worked its way out...then that could explain the tumbling sound I described in the death rattle the last time I rode. The shim could have been bouncing around in the head. If the shim is missing, where would it be now? I mean, I know it is not in its place....but it must be somewhere.

[mattrat]

I can't figure out where that shim went...I'm sure it will turn up somewhere.
The big move of the day is thatI got the cylinder back on. Head is 99% done, just have to get one last lifter done and put the missing shim back...

Pictures:
see those little cotter halves in there? that's the smallest piece of the bike, and it id holding up the entire process

Cylinder on (by the way, this can be done without a piston ring compressor)

Head gasket fitted, cam chain guide back on, ready for the head

[Jaegermeister]

How is it done without a ring compressor?

[mattrat]

the botton edge of the cylinder is slightly beveled, so if you are patient and careful, you can compress one ring at a time and push them into the bottom of the cylinder by hand.
I was going nuts trying to find a small enough ring compressor that would open up completely after releasing, and I asked a guy I know who works on 4-wheelers and small engined, and he told me that's how he does it...so I gave it a try and got them on in about 15 minutes...

[mattrat]

Well. I think I have re-assembled everything I can at this point. Starter is back in, all the side stuff (starter clutch, covers, etc) back on, breather back on. Expecting the new chain tomorrow or saturday and a few little things early next week...I predict riding Wednesday or Thursday of next week.

[Jaegermeister]

Just left a voicemail for Johnnycheese to try to schedule my dyno test and mapping. I'd like more than 18k miles before next rebuild please. Those valves were U-G-L-Y. Fortunately Austin is close to Pflugerville.

[mattrat]

one little package from bikebandit and all will be well....

[dadofthree]

[ResidentEvil]

I just read this post and Man you did WORk

[Jaegermeister]

I just read this post and Man you did WORk

Yes he did. Now that he has the tools and experience, please send your Busa engine and a stack of cash his way for rebuilds.

[Jaegermeister]

So what's up with the sprocket?

[mattrat]

So what's up with the sprocket?

partially worn - I didn't really notice until I cleaned it up to prep for the new chain. I'd replace it in maybe the next 2-3k miles - I just suggested doing it now since I have the bike apart anyway and pulling the rear wheel and changing the sprocket would be easy. I would do both front & rear at the same time, since fronts cost like $20 and they tend to wear out at about the same time.

[Jaegermeister]

Just put the final parts on and go for a few rides at Plaid Speed. You earned it. I'll take care of the sprockets later.

[mattrat]

final parts are here...pics in a few!

[mattrat]

engine is reassembled - now I just have to get it back in the bike. ugh.

Exhaust cam on:

Both cams on

Journal covers, tensioner, everything else on

and there it is...a complete engine

[Jaegermeister]

Mean looking. So, the missing shim.....dumped with the oil when it drained?