One thing I learned was the "double-nut" technique for installing/removing stud bolts. I used it to remove the stud from the model engine (came out easily). I figured I'd just test it in the cylinder just for kicks.
But when I actually did the double-nut to install it, I was shocked to find it threaded just fine! So perhaps there was something wrong with the bolt itself this whole time, and not the threaded cylinder hole.
While I did order a pair of new studs, I didn't replace the one on the other side (yet). Figured I'd leave well enough alone for now.
After charging the battery, I was getting zero-zip-zilch from the kick start. It really sounded dead. I checked spark and was fat and blue. Then I popped the drain screw on the carb and discovered it was bone dry.
Ok, so that means the problem is that the fuel line inside the carb is clogged, right? RIGHT?
So I pull the carb: detach the throttle cable, pull the fuel line, detach the air filter and the duct tape holding it together.
After doing all of that, I notice that the fuel line between the filter and the carb is also dry. Well that's odd... I open up the aux petcock - and nothing flows. Is it clogged?? NO!!!!
The fuel line was looped up and over the handlebars - the entire issue was a simple case of GRAVITY!!
Frustrating mistake. Reconnected everything, straightened out the line to let the fuel flow. And she starts right up.
Trying to redeem the session, I tried installing the brake light switch, but to do it properly you really need to remove the exhaust, and I was too drained (no pun) to do that, so it's for another day.
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