Topic: Dirty Old K1

[G3]

Engine overhaul continues.  The cylinder head is out at a machine shop to have a twisted off exhaust bolt extracted.  I've been spending time cleaning up the pistons and installing new rings.  The carbon was thicker and more tightly adhered than I had previously thought.  It took some scraping with a painters 6 in 1 tool, sanding with emery cloth, and burnishing with a Dremel.

Ring installation was a learning experience.  The diagram below describes how to install rings in a straightforward and simple way.  You will recognize the top compression ring by the shiny bevels around the edges.  I installed them with the makers mark up as many forums insist must be done, but couldn't find any official direction on this.  I believe it's a pretty forgiving system and the ring would perform fine if installed either direction.  The second compression ring is recognizably square and just a tiny bit thicker by about .001".  It doesn't have the recognizable bevel like the top ring.  Again, I installed it with the makers mark up, but again, couldn't find any technical guidance for this.  The RIK rings I used have directions for the installation of the 3 piece oil scraper on the back of the packaging.

[G3]

I'm having problems getting the cylinders over the pistons and new rings.  #2 and 3 go in slick as a whistle, but #1 or 4 always gets cocked and bound in the process.  I've had pretty good luck just pressing the rings with my fingers to get them up into the bevel and into the cylinder until the last one...

Any expert opinions on solutions?  Non-experts may also weigh in.  Thanks!

[Tews19]

Try the popsicle trick. It will level out pistons 2 and 3 to get them in first. There is a video on YouTube where a guy did it on his 550 engine. 

[goldarrow]

Try the popsicle trick. It will level out pistons 2 and 3 to get them in first. There is a video on YouTube where a guy did it on his 550 engine.

Can you elaborate? Or post a link?

[G3]

Build update:

The engine is back together.  After several tries at installing the cylinders, I discovered that there was so much carbon in the ring grooves that the new rings couldn't compress far enough to get the cylinders down.  Lesson learned from this:  don't use the spark advance nut to turn the engine--when something jams up in there, you will snap off the advance shaft.  Believe me on this one.  Use the nut on the generator instead.

Used the "engine laying on it's side" technique to install the motor in the frame.  It was super easy.  I recommend it if you're stripped down far enough to handle the frame.

Pics of current status attached.  Can anyone direct me to a purveyor of something similar to the rusty baffles shown.  They came out of the header shown.

Thanks for looking!

[Tews19]

Can't help with the exhaust but glad you have made progress and shared it with the community. 

[G3]

Still trying to figure out the maker of the 4-2 megaphones that came with the bike so I can get some baffles that fit.  I have attached a couple of better pics after they have been installed (and an extra shot that I really like).

I've been in touch with MAC.  They say they're Kerkers.  And I've been in touch with Supertrapp (Kerker).  They say they're MAC.

Anyone care to take a guess?  You can't do any worse than the "professionals".

[goldarrow]

I'm never right, so I'm going to guess those pipes are jardine

[Tews19]

Those do look like Jardines. 

[Stev-o]

Def not Kerkers

[754]

Look like Jardines.   Baffles look ok, just fix the belled end part.

[G3]

Pretty much done here.  Fired it today.  Runs a little rough but I'm sure air/fuel mix and carb sync will remedy that.  Front brake seems to be not releasing completely.  Don't know what's up there.  Still haven't found baffles to fit those megaphones.  That also probably contributes to the rough running. 

Anyway, it turned out pretty nice if I do say so myself.  Thanks, everyone.

[MoMo]

Nice restomod.  Is the color reddish/orange?...Larry

[G3]

Thanks, Larry.  Yes the color is red but it looks a little orange depending on the light.  Not bad considering I took it into the shop looking for a budget paint job.  The guy asked me what color I wanted it and I told him "whatever color you're shooting next.'"

[MoMo]

Thanks, Larry.  Yes the color is red but it looks a little orange depending on the light.  Not bad considering I took it into the shop looking for a budget paint job.  The guy asked me what color I wanted it and I told him "whatever color you're shooting next.'"

Had a friend do the same thing as that and his bike turned out great too, luck of the color draw I guess...Larry

[70CB750]

Thanks, Larry.  Yes the color is red but it looks a little orange depending on the light.  Not bad considering I took it into the shop looking for a budget paint job.  The guy asked me what color I wanted it and I told him "whatever color you're shooting next.'"

You lucky they did not have Mary Kay Cadillac next 

Nice color this one!