My first 440 "cafè'ish" build.

You could get a couple of sticks of plasti gauge and an assortment of bearings
and go to town getting the clearance just right.


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Nebr_Rex wrote: You could get a couple of sticks of plasti gauge and an assortment of bearings
and go to town getting the clearance just right.
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Lmao! That was pretty much my thoughts exactly..As much as I don't mind working only bike, this wasn't in apart of my plans for the bike this year, but it is a 30+yo motor. Ordered 4 different sets in all cause the other rod was on its way as well..smh? The mains are prestine though! Sent the crank out any ways to get the journals polished out. I'll have it back by tomorrow. For now I'm just gonna make sure all the left over bearings are gone then give the head some TLC and do a light grind on the ports, the casting inside is just bothering me to hell! The outside along the cooling fins and the plugs??OMG?..lol.Hopefully the seats wont need to be recut, I'll just lap'em and put the new stem seals I got with the gasket kit this morn.
Again..Thanks a lot for your help Nebr. I'd be bouncin off Internet walls by now trying to figure it out. Hopefully I'll be able to return the favor to you and everyone else that's helped me one day..I'll keep you guys posted...



Ed

Ummm..totally forgot about all the hardware that holds all this shit together? Didn't read anywhere if the head studs were TTY, and or if any should be replaced after coming apart? I'd like to pull the head studs off the top case just to make cleaning up the gasket surface easier..but I don't wanna gall them all up with channel locks or vise grips..

Hmmmm...after doing a search, seems I might be reusing the head studs...hahahaha..

ed

No eBay APP ID and/or Cert ID defined in Kunena configurationI used a stud puller on mine.

Are the studs metric? The link shows all inch thread.....

Was suppose to get the bearings on Friday. Saw that it was "out for delivery" woohoo!! Well...I'm still bearingless so checked the tracking number...dafuq..Bell Gardens!?? You fucking kidding me USPS?!! The black hole of post offices!?..smh..null strikes again. How does the package go from "out for delivery" to 150 miles away?? No sig required or any special hand gestures? Why couldn't my other package go through this drama?.


Ed

missionkz wrote: Are the studs metric? The link shows all inch thread.....

huh, its says metric in the listing title but it sure says inch threads in the description. look around you'll find a metric set.

Thought I'd have forgotten you guys huh? jk. Last weds. I had began a hefty and informative reply here with lots of pics, when I was finally finished I hit submit but my browser decided that it wanted to have a problem and all of the post was gone. . .smh. cookies were of no help. I gave up immediately out of frustration after that and moved on.
..Ahhhhh life..wonderful game. Anyways another attempt for an update and crappy phone pics are in order. It'll be pics with captions this time..lol
Motor torn down..gonna sandblast it.Tthe case was completely empty mechanically, just wanted to keep most of the media out as well as protect bearing surfaces more.

Stator side..

I opted not to pull the studs because, 1..my stud pullers were too small or big. 2..didn't wanna gall up the studs with visegrips. 3..couldn't find a new set. But case is blasted the best I could in my cabinet.


Stator side again..sand blasted


I should've taken A LOT more pics! But my hands were either oily or not electronic device sanitary safe 80% of the time. Had my buddy polish out the crank journals. definitely did a better job considering they have the tooling for it. no pic of though The combustion chambers..MAN there was a shit ton of carbon build up, as well as on top of both pistons. Sandblasted the bottom of the head with valves installed still so the seats wouldn't get blasted. I used my lathe to wire brush and polish each valve evenly. Wire brushed top of pistons. Speaking of,mi can't think of the word but my tops weren't smooth at all like I'm used to seeing in car engines, it was divoted (like detonation) but it was the entire surface except along the edge, it looked mechanically equal(if that makes any sense?lol) I couldn't find a pic of a new one for comparison, and I didn't want to polish it smooth. So in they went after a thorough cleaning. I used oil and assembly lube profusely. blew out all the oil holes and even pulled the 3 hex heads on the bottom case. I read the manual over and over along with the parts in front of me according to the section I was in so I'll understand and not get confused. More so in the counter weights and timing chain section...
Since it was all out and apart..out came the rattle cans..I used the fancy engine paint the has "with ceramic" on the label. Then sanded the edges..Pretty?..lol.


Gave the head some TLC before the valves and paint went on.


Motor assembled and ready to go back home.


since the motor was out and looking nice and shiney, couldn't think of putting back into the dull frame..


Well...coming together. lmao..I sat the motor on it's side in my welding chair and dropped the frame on. I reassembled most of the bike while it was on my chair. no pic though. But here's what else my tranny jack does in it's off time. Absolute help when fabbing turbo manifolds under the car..


Thinking ahead, I moved the side stand spring to the backside of it's mount to give me more foot clearance for shifting, but didnt notice the kickstand shape wasn't gonna allow it. So had to make a new one


Trying to get the angle and foot rotation just right..


coming along nicely..


So I should've taken pics when doing the header/exhaust. At this point I wanted to get the bike back together is I can ride. Did a 2-1 with a 18" rolled edge slash cut exhaust tip i normally use for 944t exhaust laying in my scrap stainless bin. Oh boy...did not like the sound of it at all!! It had an awful "tinny" sound when revving. That's only acceptable in honda civics Loli'd it with different sizes, no go. So made the insides from near scratch. Took a lot of thinking, measuring, cutting, tacking and looking (cause I wanted it to look nice too of course) but DAMN!! sounds fucking fantastic..to me at least.
Looks the part too...


Here's the inside..might remember it from an earlier pic I posted. The baffling from a Harley pipe.


Side shot with the bike complete..


Don't mind the tail light..I broke the plastic lens on the old one and needed a brake light like now..Also had to redo the seat and tail. Before they had an overhang that would cover the frame. Didn't wanna cover that up now do we? The tail is still work in progress. What a journey..lol

ed

:EDIT: I've gotta retake the header and exhaust photos. Browser keeps timing out or just having technical issues. Also, apparently on my way home after dickin around with it for a wasteful amount of hours, my brake/license plate light fell off on the freeway..SMFH!?.oh my plate was attached and went along with that trip. I just can't get a break? tried to go hunting on the freeway but it's too dark out and too many cars oddly for a Sunday? So that adventure will recommence in the am when the sun comes up.

Nice work!

header and exhaust pic update..

head pipes...


exhaust..


might remember this part. it's the inside baffling I used from a Harley exhaust I had on hand..


now one thing I failed to mention in my last update is that the motor vibrates like CCRRAAAZZYY progressively as the rpms go up. Like to the point that I my vision is blurred when riding. Other than that, the motor sounds much much better, starts right up with the choke and stays running after turning the choke off 10secs later. No leaks of any sort. Being my first motorcycle engine tear down, I give myself a pat on the back then a punch in the gut cause I think the motors gotta come back out so I can recheck the balance counterweights. It almost looks like I can split the case while in the frame still but don't wanna run into any headaches during. So guess what I'll be doing for thanksgiving?! and I'm ok with it long as the problem can be alleviated. Any tips goes a long way thanks in advance..


ed

I_Tig_in_piece wrote: so I can recheck the balance counterweights.


ed

bingo!

nice exhaust! im gearing up to make a stainless 2 into 2 for my 750twin. What settings are you using on your tig? amps? gas? do you purge? any tips for the process of cutting and fixturing pieces to be welded? i have been practicing on stainless and can get some nice beads but generally running a little too hot.