Silver Ghost Restoration-Part 19 Engine, Carbs, Exhaust

Over the past couple of weeks, I got the pistons, cylinders, heads, carburetor and exhaust back together.  It’s almost looking like a motorcycle again 🙂

I cleaned the carbon off the pistons using a wire wheel prior to putting the rings back on.

Carbon Build Up on Pistons

Before.

De-carbonized Pistons

After.

I put the new rings back on by hand.  The kit has all three rings clearly labeled.  Be sure the “top” on the rings goes “up”

Ring Kit

Ring kit.

Top of Ring 

“TOP” is engraved on the top side of the ring.

Then, I heated the pistons in the oven (175) and put the wrist pins in the freezer to make it easy to push the pins into the pistons.  I bought a new set of C-clips and inserted them being sure the gap in the C-clip didn’t align with the cutout for removing them.  There is a mark on the piston top “VOR” that indicates the side of the piston facing forward.  Be sure you have them aligned correctly when assembling on the connecting rod.

C-clip On Piston

C-clip covering the cutout in the piston.

Piston on Connecting Rod

Wrist pin assembled onto Piston and connecting rod.

Next, I assembled the push rod tube rubbers onto the ends of the tubes aligning them as shown.

Push Rod Seals

Push rod tube rubbers aligned.

Then, I put the base gasket on using Hylomor as the sealant on both sides of the gasket.  Be sure the holes in the gasket align with the holes in the base of the cylinder.

Base Gasket w/ Sealer

Base gasket with Hylomar sealant before smoothing it out over the gasket.

By hand, (I don’t have a ring compressor) I pushed the cylinder over the piston.  You can do this by hand if you are very patient and go slowly so you don’t break a ring.  I found using two wood sticks made it easier to compress a ring on one side, wiggle the cylinder a little so it covers that side of the ring then press the opposite side into the ring gap and wiggle the other side of the cylinder past a ring.  Easy and slow does it here.

Assembling Head

Cylinder over the piston.

Next, make sure you get the head gasket aligned the right way so it doesn’t cover the push rod openings.

Incorrect Base Gasket

INCORRECT – gasket covering push rod tube holes

Correct Base Gasket

CORRECT – no obstruction of the push rod tub holes.

Next, attach the head by sliding it over the cylinder studs and put the push rods into the push rod holes.  Then, add the rocker arm assemblies and using a cross-over pattern, tighten the nuts on the cylinder studs to pull the cylinders down onto the engine.  Check as you go that the push rod rubbers are aligned with the holes in the block, or you will crack them and have to replace them.

 Inserting Push Rod

Inserted push rod.

Assembling Heads

Rocker arm assembly attached to cylinder studs.

Assembling Heads

Cross-tighten nuts on cylinder studs to pull cylinder into the block.

Next, follow the torque tightening sequence and tighten the heads down.  Torque is brought up in stages, not all at once.  When that’s done, set the valve clearences, add the valve covers and move on to the other side.

Cylinder & Heads

Cylinder & Heads

I added the carburetors using the rubber spigots and then assembled the new exhaust system.  I found that assembling the muffler to the header first was the best way to go.  I had some troubles with one of the inserts that goes on the header pipe as it wasn’t round.  I finally got it back into shape.  Keep all the connections loose and attach the muffler to the rear mounts.  Then, be sure the header is pushed all the way into the head and twisted so the cross over pipe goes on.  This took some fiddling, but it finally goes together.  On the right side, I had to remove the brake peddle and grind a little off the the top of the peddel casting so the peddle would move freely.

Right Side - Almost an MC Again

Right Side.

Front - Cylinders and pipes

Front showing cross over pipe.

Left Side - Pipes & Carb

Left Side.

I’m replacing the choke cables and have to wait for them to come in before putting the air cleaner and housing back onto the engine.  That will complete the engine assembly.

Next up, paint preparation and finally, shooting the paint.

 

Compression

Recently, my wife and I took a two week vacation driving from our home in Colorado to the upper pennisula of Michigan to a “traditional” music festival.  The tempo and meter of life was different.  Instead of the cadence of a work day, we had the cadence of a driving day.  Instead of keyboards, cell phones, marketing videos and conference calls, dictating my attention span, my mind was engaged listening to the CD player and having conversations with my wife.  Time was measured by conversations about random topics and the rythmic hum of miles accumulating on the odometer.  The screen in front of us was Wyoming, South Dakota, North Dakota, Minnesota … big sky and rolling land.  We didn’t tune in to the news, web or blogs.  We tuned into driving, thinking idle thoughts, and listening to music.  Decompression.

Upon our return, I noticed the rate of content bombardment went up … way up.  I plugged back in to — email, news papers (yeah, I’m one of those), blogs and very limited TV (The News Hour).  The transition was stark.  Time was now measured by the pace of electronic connectivity rather than scenery passing by.  And if I was in my 20’s and totally connected, the rate of input would have been much higher.

It dawned on me that compression not only has to do with how time is metered out, but how information is concentrated.  News of events now is worldwide.  I can see in 20 mins a range of events that covers most of the surface of the Earth and reflects the pain, anger, anxiety and hatred of 6 Billion folks.  40 years ago, I couldn’t read about more than what was happening in my local community and a small amount of national and even less international news due to the size of a newspaper printed once a day.   That constrained the content I was exposed to enormously, and even more, the culture and norms I was exposed to.

So, what happens to your sense of balance, happiness, well being and confidence about how the world works when compression includes not just time, but the events of the entire world updated every 20 mins?  We know that the majority of the “popular news” is about pain, anger, anxiety, hatred and conflict, rather than dull, non-emotional stories.  What happens when you get that kind of input, world-wide, updated every 20 mins?  Does it change your perceptions, attitude, and outlook on life?

I wanted to draw attention to the fact the negative things people do to each other, they have always been doing.  But, you didn’t see very much of it since the scope of information you could access was pretty small.  Today, that scope is global.  Is the world and its people more, or less, aggessive towards each other?  Hmm …

Silver Ghost Restoration-Part 18 Zen and The Art of Motorcycle Rebuilding

I started on this project last October and have been chipping away at it as time permitted.  Last week, I had a four day weekend and spent time preparing for painting, aka, priming and sanding.  This has taken much longer than I expected, and I’ve been recalling Robert Pirsig’s “Zen and the Art of Motorcycle Maintenance“.  I’ve experienced several personal “gumption traps” and found that “being in the moment” is not easy to accomplish in a consistent manner.

The paint preparation phase has exposed a couple bad habits I have.  The first is hurrying, the second is not thinking it through and the third is pushing to complete when I should take a break.  These are related, and if I recall, are called out by Pirsig as examples of gumption traps that impede attaining quality.

Hurrying usually results in getting “behinder” due to mistakes and the rework they require.  On top of that, you’re attitude is not postive due to your inner voice of self critisim getting pretty loud.  The fun factor goes way down.

If you don’t stop and visualize getting from what you have to what you want, you can find the path you take is the wrong one, or you aren’t taking the shortest path to do the work.  This is more the case when I have been working on disassembly and assembly of the Grey Ghost, but I find it happening in paint preparation as well.  For example, I’ve forgotten to clean spray nozzles, not had the gloves on, forgotten to clean the parts with Windex prior to priming and each of those are the result of not thinking about how to get from what I have in front of me to where I want to end up BEFORE starting the work.

I also find that “getting done” is a slippery gumption trap.  Getting done, of course, has value and does provide gratification.  But, the journey also has great reward, and a journey done well has an even greater sense of accomplishment.  I’m starting to figure out when the “let’s get done” motivation is out of control.  And every time I don’t listen to that inner voice that says “Hey, you’re getting tired of what you are doing, take a break”, and keep on working, inevitably s&^%t happens.

I think there are days when you should not work on a project.  This past Monday was one of those.  I managed to break the coffee pot, assemble something backwards and put my finger prints in wet primer … all in about an hours time.  I quit for the day at that point.  It seems that Monday was not a day where I was “in the moment”; perhaps I was distracted by thoughts of a family get together later that day, or thoughts about the impending return to work drowned out “being in the moment”.  For whatever reasons, the Zen state required for good quality was not in evidence.

Here is an observation about our ability to recognize the qualityof our work.  Paint preparation (the mundane) really shows how quality (the sublime) is achieved: many small things done well result in high quality.  I’ve sanded several areas and had to refill them because the surface was not the right contour or small defects were evident in the body putty.  Each time I re-primed those areas, I’d think “There, that’s got it”.  And then I’d re-sand it and see another small defect I had missed, and I’d say “Well, that’s not enough to make any difference”.  But, the next day, I’d look at that area again, and it was clear it wasn’t up to snuff.  So, I’d go back and put more body putty over it, prime it and sand it again.  In one area of the tank, I’ve had to repeat that process 4 times.

My point is we see quality, or the lack of it,  in an instant.  But, we also have built-in “reality filters” that allow us to pretend we achieved it when we really haven’t.  The pursuit of quality demands an ego-less perspective on our own work, which for me, isn’t easy to achieve.  There is an absolute ego-less honesty required about your work if you want it have high quality.  Achieving that honesty is worth the journey, and in no small part, it is what Zen and the Art of Motorcycle Maintenance is all about.