The simple task was to tighten down the exhaust flange bolts after having realized that Roxy's were full tight. I thought the excess noise and smoke from the head was coming from it being too loose.
While cranking down the upper bolt, I suddenly realized that it wasn't actually tightening at all. I pulled out the bolt and saw metal shavings. So... the threads are completely gone. I tightened up the lower bolt as much as I dared.
I hooked up the battery and tried to start it anyway. Nothing - totally dead. Sat and thought on it for a few minutes, and just when I was about to pack it in, I decided to try it WITH the choke. And she started right up!
She wouldn't hold idle, but starting was no problem.
So is this related to the exhaust being loose? It was the only thing that changed, and yet why would she start and run with throttle, but not hold idle.
The fact that it took choke to start her this time means she's running much leaner than before. Could that point to the exhaust?
Started doing research on thread repair. Looks like there's the more common Helicoil option for only $20 or so, or there's the higher-end Time Sert kit for about $70, though it's said to be much better long-term.
Both options involve having to carefully drill into the head, though.
But like Pirsig said in Zen and the Art of Motorcycle Maintenance, the entire value of the bike is now hanging on this one stripped bolt hole.
Decisions, decisions...
Also, found a mix of oil and gas in the pan since the last run. Clearly the carb had overflowed and drained to the pan - and I realized I'd also left the petcock switched on on the aux gas canister.
But when I loaded up the gas again, nothing leaked. So I set up the overflow line into a separate plastic container and left gas in the canister to see if something leaks over the next couple days.
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