Engine Rebuild Questions

Can't you collapse the push rod tube, reset the O ring to the groove, then put it back in place? You shouldn't have to mess with the head to do that, unless they changed the design on the push rod tubes.

The blast uses a plastic fiberglass pushrod cover which won't fit unless put on before the cylinder head. It doesn't seem to be leaking much at all yet so hopefully it stays that way.

On the machinists recommendation I took the bike for a ride up into the hills on Skyline road, went really well. I am working on getting the bike broken in correctly and from what I hear you want to use a lot of loading of the engine and engine breaking. Well I did that and on the way back home the bike started not running right, felt like it was getting "false air" but I checked the carb boot and it is fine. I'm going to reseat the exhaust and see what happens. The problem might also be a bad ignition connection or something also. Hopefully I can get it running correctly today even though it will be too hot to ride on a fresh engine.

Thanks for the help and suggestions and I'll keep you folks informed as to how it goes.

OK, found that the throttle position sensor wasn't hooked in all the way, I put it back on and now the bike runs again. I still hear what sounds like an air leak at the exhaust manifold, I might have to reseat the exhaust. Another issue is the bike want to stall out when warming up so I might have a small tuning issue.

It has also been too hot to ride a fresh motor as I hear overheating a fresh engine is a big no-no. I have to ride in the evening when it is more conducive to air cooled bike break -in. I am doing the first oil change at 60 miles and glad because the oil is coming out black with junk in it and I didn't use much assemble paste.

Thanks for all the help folks and hopefully I get a summer of riding this year, last year I crashed and busted my foot and thumb which laid me up for 10 or so weeks. Now I have a freshed up motor, good used forks with new oil and seals, a new straight rim, new tires, and the bike is ready. Next to go is front and rear HH sintered pads and a new clutch. I adjusted the clutch and I'm pretty sure it is dying a slow death. The clutch isn't a big deal but when it slips and kicks in it can be a bit unnerving.

I have used 30 wt oil and STP 1:1 as assembly lube. No idea if it worked or not.

Well the weather here isn't good for the garden but it is cool enough to ride on the fresh faced buell. I have been riding hard and fast so back to normal basically. The bike isn't leaking any oil but might be using a bit. I don't think it is an issue, I actually think the tank oil dipstick might be leaking a bit which is where the oil is going. I do smell a bit of the 15-40 diesel oil burning off but I'll just assume all is good for now because I don't see any smoke.

All and all I'm happy with the way the "rebuild" is going. I do need to change the front brake and clutch pretty soon though and go through the shifting mechanism, but that should be an easy job and I won't need a machinist. The punky buellster isn't really the most sophisticated bike so a bit of slop is expected especially in the shifting. When I first got the bike I had a clutch that was pretty good but after beating on the bike for 25k miles I turned it into a slipper clutch. The clutch is kind of funky in that it won't really stick unless you really drive it hard. If I ride it slow the clutch will slip and buck, but if I pop the clutch and ride hard it sticks and does the job. I just figure I'm "breaking the glaze" when it slips a bit. I did adjust the clutch when I changed the cable/primary oil so it should be with spec. Sometimes you have to use the spec which works for your particular bike is what I'm thinking.

Thanks for all the help and suggestions folks I appreciate it. This is definitely the ugliest loudest and nastiest bike on the block now. A neighbor moved in with a newer Kawi zx? and the guy up the street has a ktm offroad but my bike is the loudest and nastiest on the block. I see hate in peoples eyes when they hear this beast. I love blasting past harley riders also. Aside from the sporty most harleys look a bit constipated and sluggish to ride.

If it sticks when your beating on it then you'd better look hard at the bearings and thrust washers on the clutch shaft. Sound like its walking out due to helical teeth.

OK today I went to walmart to support americas #1 employer, and I noticed a bunch of smoke coming out of the punky, it turns out the PCV valve was out of the gasket on top of the valve/pushrod cover and was making a "whoosh whoosh whoosh" sound. I pushed the thing back in and now no more "air leak" and also no more metal ting

All I need to do next is fix the stupid exhaust leak, thanks taiwanese 1.75" muffler! I might buy a real muffler that is 1.75in instead of an Asian metric sustitute.

Thanks all and anyone in the SF bay who wants to meet the punkyest buell let me know!

OK I've done about 500 miles without too many issues. I have changed the oil twice. I just had to change the damn PCV valve as it actually cracked and wouldn't seat. The damn PCV came apart when I removed it and fell into the rocker cover. I got the junk out luckily.

I'm thinking about riding my bike up to my Moms but it entails about 200miles of highway riding. Is there any consensus about how many miles until you can ride on the freeway? I'm pretty sure the bike should be good but was curious what you guys think. I am going up there because there is a bitchin bike run through Downieville/Quincy and my mom asked if I'd like to ride the squirrely 1200 while she rides the road king.

Thanks for any help or suggestions!