Fixing oil suckage in 2003 (project for a friend)

[GIXERHP]

As for the valves,, until you remove them you wont know if they are bad.
I where you just sent the complete head out for a valve job!

[mattrat]

As for the valves,, until you remove them you wont know if they are bad.
I where you just sent the complete head out for a valve job!

valves are ...interesting...

cylinder1 is the worst of it...

can these be cleaned?

cylinder 2

cylinder 3

cylinder 4

Not sure Mr. Jaegermeister has the budget for sending it out..That's what I'm here for!

Cylinder 1 was where all the noise was coming from - that huge buildup on the exhaust valves was probably it. Nothing broken that I see...I'll measure all these valves to test runout but I don't think they are hat worn...just gunked up.

I think the valve oil seals and rings are shot. those will be replaced, but the buildup is a problem - even if I clean everything out it will just start again - how do I stop this?

[GIXERHP]

All exhaust valves are going to have build up! Are you capable of lapping the valves, to freshen the head?
How many miles are on the bike?
As for the rings, yes, replace them, as for the oil consumption problem, the valve stems seals, was most likely the problem!

[GIXERHP]

Also, tell your buddy not to run the cheapest gas he can find!
The bike only requires 87 octane but dont buy the gas from the cheapest places!

[Jaegermeister]

Also, tell your buddy not to run the cheapest gas he can find!
The bike only requires 87 octane but dont buy the gas from the cheapest places!

The bike has about 18k mi I believe, and I bought it about 2500 mi ago for $4950 on Ebay, about 250 mi from home. I am thinking the previous owner knew something was up now. I bought it Thanksgiving. So I have only run super-unleaded since I got it....but the damage was prexisiting. It began a low rattle very soon after I got it which I thought was the cam chain. Then two plugs fouled, then the rattle went from annoying to uh-oh wtf in about 5 miles one day. I thought I was lucky to get the bike, myself and my wife back to my garage still functioning.

[mattrat]

All exhaust valves are going to have build up! Are you capable of lapping the valves, to freshen the head?

yep - once I am sure the valves are straight, I'll take care of that. any reccomendations on which lapping paste for this head?

[GIXERHP]

yep - once I am sure the valves are straight, I'll take care of that. any reccomendations on which lapping paste for this head?

I use a finer compound, and just keep working at it!

[mattrat]

relapped the valves in the bad cylinder. now just waiting for some tools and new gaskets and we'll start reassembling.

[mattrat]

oh, and I got that old chain off!

[Jaegermeister]

Guess I need to Google lapping. I thought that was passing someone and being a lap ahead. Now I need to know lapping a head.

[mattrat]

Picked up PAIR valve blockoffs on ebay - one more piece I don't have to reinstall...
also received new rings and exhaust gaskets. just a few more pieces to needed before I begin re-assembly.
I'll post some more pics once I figure out where I put my memory card...

[mattrat]

Pair Blockoffs

New Exhaust Gaskets:

New Rings:

and a bunch of chemicals just waiting to get into the bike:

[Jaegermeister]

Great to see stuff going ON now instead of all coming OFF. I must check 5 times a day for new updates.

[dadofthree]

You would have liked GMBusa's block offs. From the pictures it looked like Paul cut the tubing coming out from the cylinder wall flattened and folded it over and brazed it. From memory.

Enjoying this thread.

[mattrat]

Today's goal:
-stand by the mailbox and hope the gaskets get here
-install new rings on pistons

Still waiting for valve guide tool (just to get the new valve oil seals installed correctly), Cylinder Head and Base gaskets, along with starter motor cover gaskets, new chain, and I need to find the chain rivet thing...and need to pick up piston ring compressors...

Just trying to stay organized. If all the parts come in as expected, this thing could be reassembled and ready to go by next weekend. No Promises, though!

[mattrat]

installed the new piston rings - when you do this be sure to align the gaps correctly - 120 degrees apart so no two gaps are in the same spot on the piston.

first ring and spacer go to position 1
second ring and lower sideraio go to position 2
upper side rail goes to position 3

[mattrat]

I got the valve tool and a couple of side gaskets today- tomorrow I'm going to reassemble the head now that I can get the new valve seals in.

[Jaegermeister]

so the part that fell off on page 3 that goes behind the sprocket cover....is it as beat up as it looks? and what beat it like that?

[mattrat]

so the part that fell off on page 3 that goes behind the sprocket cover....is it as beat up as it looks? and what beat it like that?

It's a rubber spacer - and it's not beat up, just caked in grease and dirt. I cleaned it up and it's fine, It goes under the sprocket cover and it's going to get all grimy like that. You should see how much crap I cleaned out of there.

[mattrat]

base gasket and head gasket arrived today. I got nothing done since my dear wife needed help planting the garden...