Work Underway This Winter:
- Removed tank, pipes and rear cylinder to replace weeping base gasket
- Removed front rocker box and lifter block to replace
weeping lifter block gasket
- Removed inner and outer primary to replace shift lever attached to
splined shaft coming out of transmission
- Replace shifter linkage rod (ball-ends worn out)
- Replace engine guard (bent too many times)
- Replace speaker covers (worn through)
- Fix worn-out saddle (mostly duct tape now)
- Replace worn-out throttle cable
- Maybe install Stage II components
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Notes/Questions On Work:
- No honing of cylinder or re-ringing piston
- Only about 20K kms since last done
- Replace studs
- Base gasket began leaking
again after only 20K kms, so these are suspect
- Replaced shifter lever but not shaft from transmission
- Red loctite and extreme tightness of grade 8
bolt should hold lever secure, given new lever with fresh knurling
- Will likely get seat rebuilt
- Important for height not to increase
- Have some reservations about installing Stage II components
- Already have Stage I installed
- Do not have chip for
flashing ECM for Stage II
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Base Gasket, Lifter Gasket and Shifter Repair
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Work in progress
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A cheap tool for aligning lifter blocks
(using brass ferrule over alignment bolt)
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Splined shifter shaft wear
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Old shifter lever wear
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New shifter lever
(red loctite on shaft and tightened to shaft
to max. torque, using grade 8 bolt)
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Stud removal method
(2 nuts locking on stud, 2 wrenches for leverage)
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Throttle Cable, Stage II, Sporty Foot Peg
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Nearly worn-through throttle cable
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Used Stage II kit components
(broken oil pump gear also in picture)
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New foot peg for Missus' Sportster
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Starter Issues
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Starter removed
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Broken-off bolt in starter shaft
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Fitting starter back in
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