Run Red Run: We Got Spark!

I think the four big milestones (for me personally) on any restoration are these:

1. Getting through the whole title and registration process.
2. Getting spark.
3. Getting to idle.
4. Shifting through all gears.

Two down, two to go on Red since today she threw a big fat clean spark on the very first try.

First went through and finished off installing the clutch and other bits left over from mounting the engine.  Also checked static timing and it was still spot on from before.

Wiring was straight-forward (why did it seem so much more complicated before).  Coil wire went to battery positive, battery negative got grounded to a cooling fin.  Tied the spark plug up against the head and turned it over and got nice fat sparks.  This was on a used plug.

Also installed both pedals, foot pegs and exhaust, so she's got all her big parts now.

Run Red Run: Engine Install

After all the back and forth around possibly installing the motor to Astrid or Evie first as a test, decided to just cut to the chase and mounted the motor straight to Red.

First things first, swapped out the smaller bullet on the coil for the bigger red one.

Install itself was relatively painless, though the trick is that you have to set the rear in place before the front.  Had the coil wired up through the battery box and just made sure to pull up the slack as I slowly pushed the engine into place.

Added the top end and the exhaust.  Added the step bar so I could ride the sidewalk a few times, but really need to add the pedals to get a good feel for the ergonomics.

Run Red Run: Exhaust Test on Ivy

Tested the new muffler on Ivy.  Works and sounds great!

Evie: Rolling Chassis!

Big day for Evie as she gets built out to a rolling chassis.  Except for the main stand pipe and the rear axle, all the other parts came right out of the bin!  That must be some kind of milestone for the shop...

Had been making a checklist for the past couple weeks and supposedly had everything we needed.

Swingarm went on with no issues.

Hit the very first problem with the main stand.  Looks like the bracket had been bent (impact?) and so the holes were not completely aligned.  Took about 3 whacks with the dead blow to straighten it and then the pipe dropped right into place.

The bigger challenge came with the steering head.  Neither top nor bottom race was in the frame so they both had to get installed.  Ended up using the new ones that came with the set of new caged metal bearings.

But with everything in place, the tube would not come up far enough for the top nut to grab it.  Realized that the top race was only sitting flush to the top of the frame but needed to drop inside a few more millimeters.  Luckily, the 30mm socket was a perfect fit to whack it down into place.

Cranking down on the top thread also seemed to force both races to seat properly (though I cringe to think of what was happening to the bearings).

Next problem was the right side threads at the top of the cushion, which were almost completely perished.  Really thought there was no chance of getting the bolt to thread, but going very slowly and applying pressure, finally got it on.

Caught another lucky break with the rear wheel as I realized that the drive flange didn't have a bearing in it.  But had one in the batch I was meaning to actually throw away (never throw stuff away!!)  Knocked it in and we were back in business.

Rear wheel went on without any more problems.  Then mounted the Bridgestone Battleax to the front rim.  Skipped the rim strip and also just used an old 2.50 tube that appeared to have been patched?

Was disappointed to see the Bridgestone "crack" as it went on... like little hairline cracks.  Maybe the tire was no good in the first place?  Can't remember if that seller said it had been sitting for a long time...

But at least it went on rather easily.

Front wheel also mounted without too much drama, except I was missing the proper axle spacer.  But ended up using the bottom race that I didn't need for the steering head!

And she rolls!

Run Red Run: Engine Work

Swapped out the worn cam roller for a good new one. 

Also added the new +0.25 oil ring to the P1 piston. 

Odd Jobs: Tires, Mufflers, New Frame

Miscellaneous odd jobs:

• Unbox the misc bits and bolts from Ebay.  Score a roller, engine bolts, clutch lifter and some decent screws and bolts.  All the 5mm screws were JIS!
• Tire pressure to 30 for all 4 bikes
• Unbox the new muffler and finally make one good one for Red (no baffle)
• Revisit the engine guard for Ivy.  Marked off the section that would need to be cut down so that it doesn't hit the muffler.
• Unbox the new blue frame (but didn't unwrap it)

Run Red Run: Head Cover

As predicted, once I had the head cover bolted down, the camshaft went in easily.

Added more gaskets, including the clutch cover.  Took an hour to painstakingly peel the old one off with razor blade and decal scraper.

Also tested mating the new header pipe with the muffler.  Fitting was no problem, but disappointed to discover that the edge is cracked off the header where it meets the exhaust port.  Wondering if that will have any effect on performance.

Thinking to test it on Roxy...

Run Red Run: Camchain and more

Spent a long day on the carpet...

• Main goal was just to add the cam chain and the new roller bolt I got from eBay along with the other misc cam bits.
• Discovered that the other misc cam bits were in much better shape then what I had installed.  The oil sprocket had very sharp teeth compared to the rounded off one I had.  Also swapped out the retaining ring.
• Also started adding in more gaskets.
• But ended up with an odd problem where once I added the rectangular rubber gaskets on jug and head, I couldn't get the camshaft in because the head was slightly out of alignment.  Had a hunch that I needed to tighten down the head cover to get it compressed enough...