It includes assembly of the front forks, seat, fenders, battery box, installation of the handlebars and cables, and odds and ends that I felt were better covered in this write-up rather in a separate one following the parts fiche breakdown I use for cataloging my write-ups. I include links to other write-ups where applicable to explain a particular procedure.
Here is a short video of a walk-around of the finished bike followed by some pictures.
Rear Cowl Decal and Roundel
Inspection Sticker and Tire Information Sticker (From Heritage Stickers)& Original Seat Sticker
Cockpit with Instruments and Original Dash Stickers
Carburetor, Tygon Fuel Lines, Engine Badge and Polished Engine Housing
Previously, I removed the heads, cylinders, pistons, rings and connecting rods. I installed new rocker arm needle bearings to replace the broken bearing cages. I disassembled the heads and inspected the valves and seats. You can read how I did that work here.
I had the Nikasil cylinders replated and honed to match the new high compression (9.5:1) pistons. I had the connecting rods refurbished and I had the heads rebuilt. So now it’s time to put it all back together again.
The cylinders had the push rod tubes and the two short studs at the 12:00 and 6:00 position of the heads removed, so I also have to install them.
I started from this:
Ready To Remove Heads & Cylinders
Engine Out of Frame
Piston Crown with Carbon
Score in Right Cap Bearing Sheel
Right Side Crankshaft Throw
Left Exhaust Lower Rocker-Recovered Needle Bearings and Cage Pieces
Right Intake Rocker Busing
Right Intake Rocker Shaft
Valve Assembly Components
And finished with this:
Push Rod Tubes Installed
Piston with Rings Installed
Sliding Cylinder and Piston onto Long Cylinder Studs
Ready to Snug Cylinder to Engine Block-Push Rod Tube Rubbers Started
These write-ups cover disassembly of the handlebars, forks, steering stem, steering damper and fork lock, rebuilding and restoring the wheels, wheel bearings, fork damper rods, fork sliders, steering stem bearings, fork lock, steering damper and installation of a new Toaster Tan top brace and steering stem “acorn” nut.