THE GOOD BUCK

I’ve been tinkering every morning and on my one day off today I’ve battered some jobs on the Harley.

I managed to get the engine out and split today. The great news is that apart from some staining and sticky bits of oil, there doesn’t seem to be any damage. After seeing the sludge and metal shavings on the sump plug I was expecting at some point to come across a pile of smashed metal and gunge.

I’m happy with that. I gave it a clean, scraped all the gasket off, sandpapered and cleaned it again, then started the rebuild. Once I had the cases back together I got carried away and continued, I fitted the oil pump, the cam gears, a new gasket, a new set of allen bolts and the cam side casing. That was a huge relief as that had the one bolt I’d had to drill out and I was scared it was going to strip when I tried to tighten it.

I’ve had a hell of a day off.

Happily, since I’m having to buy all my tools again but in imperial, and the Harley was £2,000 to start with, work has suddenly gone mad. 4 shifts, 6 shifts, 5 shifts for next week. I certainly can use the money but it’s making working on my bikes a lot harder.

Anyway, I was off today so cracked on. My goal was to strip the heads, check the valves and the barrels, and check the cams for timing.

I’ve had some successes but a big problem. I’ve been working so I’ve not had the time to do too much, today was my day off and the engine start spray arrived yesterday so I did some work on it. I bought a cheap trolley jack with support cups to lift the bike up by the frame so I could take the forks off. It wasn’t what I was expecting. I thought it was a full length platform to lift the whole bike. Nope. It fits across the bike and just raises one end or the other. Meh. I can make that work for most jobs. Then I went to slide it under the frame and because of the raised cups it wouldn’t fit! I had to angle grind half of the raised legs off before I could even start. Anyway, I got the forks off, finally got the seal covers off and the seals out.

I think they were due for a change.

That’s the good.

Today I cleaned and washed the carb after it’s overnight soak. I put it back together (missing a part, dumbarse) and tried it. Still not running, so I started on the other jobs. I pulled the front brake off, stripped and cleaned it, put it back on then bled it. I tried to do the same with the rear brake but it’s got Torx bolts. I don’t know if Torx come in imperial but mine were slightly loose and the bolts are set solid. I didn’t want to strip the head so I’ve ordered some Torx sockets. In the meantime I bled the brake. I pumped the tyres up. It rolls forward and back now without too much resistance (other than it’s native standing mass, obvs) and the brakes both work. I remembered to test and both my brake lights work. Brilliant. I need to fit indicators but so far the only thing electrical thing that isn’t working is the horn. I’m happy about that because I hate electrics.

When I put the carb back on I noticed one of the throttle to carb cables was slack. I was worried I’d done something wrong. I’m having issues with fitting the choke cable back in position as well. It’s one 17mm nut. What can possibly go wrong? Yet it doesn’t seem to want to work. Odd. Anyway, when I noticed the part of the carb I’d omitted (left it drying in the sun) I popped the carb off and rebuilt it. The slack cable came away in my hand. It had snapped in it’s sleeve. I’d already ordered a new set, but it was good to see it wasn’t me.

I’m working my way through the peripheral jobs (it all needs doing) as I’m trying to get the engine started. I’ve ordered a cheap trolley jack (with support cups to position under the frame) and a fork seal and dust cover set. I’ll pop the forks off, drain the fork oil, clean inside and then put fresh oil, seals and dust covers on.

Day One:

I dropped the van off this morning then cracked on with the bike. I’ve fitted the new battery, hotwired it, and I got lights, (low and high beam and clock and rear light, forgot to test if the brake is working) but no horn yet. The engine turned over nicely, sounded like good compression. I didn’t have any spark at the plugs though. I gapped the plugs and traced the wiring, the leads to the distributor were loose so I tightened them, SPARK!

It still wasn’t firing so I took the air filter off and gave it a wash, then took off and stripped the carb.