Ivy II: Oil Leaks

On closer inspection, realized that I'd never installed the left cover gasket in the first place.

Drained the oild and added the last one no-extra-hole gasket from the green binder.  Ran her again but was now getting a localized leak from the middle right.

Drained the oil again and on even closer inspection, found that there was some damage (probably a gouge from a broken chain?) that had caused an irregular surface on the crankcase.

Popped out the alternator and carefully filed the protrusion down until it seemed flush and level.

Refilled with fresh oil (650 mL) because the old stuff was already looking pretty dirty.  Ran her again and no big leaks!

But... came down a couple days later to find a pool of oil in the pan.  Looks like a slow leak coming from somewhere in the left cover even with a cold engine.

Ivy II: Fire Test Go!

Playing with the new soldering iron.  Made the static timer a lot more bulletproof.

Downstairs, added the alternator gasket, tighten the camshaft and advance bolt.

Torqued head cover bolts to 10 ft.lb.  Too gun shy to go higher but maybe will go up even slower to 14.

Added 850 mL of fresh oil.

But initially, was getting nothing trying to kick it over.  Wasn't even coughing.  Was cold, too, in the mid fifties.

Then reset the air screw to 1 1/4 turns out (from 1 1/2) and suddenly she fired.

Let her run for a few minutes until noticed a giant leak from the left cover.  But left that for another day.

Ivy II: Got Spark!

First of the Three Trials passed.  We've got spark.

Didn't even have to adjust the points at all.

Ivy II: Top End Install

Piston back in with a little moly-B.  Replaced a few gaskets that looked perished.

Torqued the rotor bolt to full 20 ft-lbs.  But a little gunshy on the head covers - only torqued to 5 ft-lbs.  Will slowly increase torque bit by bit before running.

Ivy: Motor Swap Day

Had a clear Sat afternoon to work on swapping the motor from the old original Viola to the new Monkey Motor.

Surprisingly painless.  After removing exhaust, pegs and kicker pedal, simply dropped the old one out.

Noticed that the rear screw on the ignition coil was almost all the way out!!  Note to self: use lock washer and/or loctite on those screws.

Removed the tank and laid her down and mounted the new motor after running the coil wire through the frame.  No problem with fitment.

Next, test for spark and then for oil leaks.

Red: Roadside Repair

Proving that one should always carry zipties!

Going down along Anza on the way home and heard a weird "clinking" noise.  After a few blocks, realized it was the headlight rattling because it had lost the right side bolt on the mounting ear.

I thought I'd actually lost the mounting plate itself, so I rode back all the way to where I'd turned but didn't see it.  Only after getting off the bike and making a closer inspection did I see that it was still there on the bike, stuck to the rubber.  Lucky...

Zip tied the mount back into place.  Realized that maybe the zip ties were actually a better way to go than the very fiddly nut and bolt.

Red: Headlight Grill Chop #2

Drilled out new 8mm holes in the headlight grill.

Started out with the step bit just to make a solid indentation.

Then switched to the DeWalt bits and just started with the smallest and worked my way up.

Finally, went back to the step bit to clean up the hole and smooth out the edges.

Came out trick.

Mounting was fiddly.  Ended up switching to 3 washers for spacers as the ones that came with it were now too wide.