Topic: K8 Highway Racer - Finished

[SOHC4 Cafe Racer Fan]

Such a better ride than that Enfield.

Thanks bro!

Special thanks to forum member Ted ( Ricky_racer ) for providing the engine bolt and conversation. It was a pleasure to meet such a good guy and shoot the #$%* for a little bit.
Also, big thanks to this forum and the ton of knowledge it supplies. It's made this project a success.

Ted's a good guy.  I haven't had the chance to meet him but have exchanged messages over the years.  Great guy to know in San Diego.  I thought he was possibly moving.

[JoeCooley]

So bad news guys. I think I broke my cam and/or bent valves. Rockers on #3 &#4 don't move when cranked over and exhaust is coming out the carbs. #$%*ing #$%*! 😠

[JoeCooley]

I have a spare head and 72k camshaft though. Just have to source an 836 headgasket and frame kit. Hopefully the pistons are ok.

[calj737]

So bad news guys. I think I broke my cam and/or bent valves. Rockers on #3  don't move when cranked over and exhaust is coming out the carbs. #$%*ing #$%*! 😠

It breaks my heart for you read that. Fingers crossed the damage is minimized.

[rickmoore24]

Awww, dangit.......

[JoeCooley]

Ok so the engine is out. The camshaft is broken. Definitely oil starvation on 3&4. Not sure what caused it but I will clean everything and make sure the oil holes aren't blocked.

[Restoration Fan]

Contact Bill Benton.  He has another 78 camshaft and more valves to replace them.  Great guy who will give you a fair price as well.  He's a member on this forum.

[JoeCooley]

Contact Bill Benton.  He has another 78 camshaft and more valves to replace them.  Great guy who will give you a fair price as well.  He's a member on this forum.

Thanks first the tip. I already have another head that's been rebuilt and a 72K camshaft. I plan to get all back together this weekend.

[JoeCooley]

Ok last one before its back to work.

[Desert-SOHC]

I had one break too, rebuilt it on the kitchen table. 

[JoeCooley]

I had one break too, rebuilt it on the kitchen table.

I'm doing all this at the hobby shop on base. It sucks not having a garage. I'm restricted to thier hours. If I had a garage I'd get things done much quicker. Hell, I'd be working till like 2am...

[JoeCooley]

Update: The engine is back together and in the bike. I ground down the bottom front mount flange before fitting the engine. OMG it made it soooo much easier to install. I'm glad I didn't bother with the frame kit this time. I still may do it in the future, but I don't feel right about cutting a good frame and sacrificing frame rigidity. I ride pretty hard into turns when I'm in the mountains.

Ok so just a few more bits to attach and I should hear it fire tonight.

[rickmoore24]

Glad it's almost back together! IMO the frame kit is clutch and would make a job like this a breeze, I installed one to tackle a small oil leak the developed on my top end 7 years after my re-build and the frame is no worse for wear with a kit installed. I used Franks (754) no weld kit and it's done quite well on all my rides, I don't notice a difference in a similar bike with or without a frame kit that's fitted properly. The suspensions, now that's another story. 

[JoeCooley]

Glad it's almost back together! IMO the frame kit is clutch and would make a job like this a breeze, I installed one to tackle a small oil leak the developed on my top end 7 years after my re-build and the frame is no worse for wear with a kit installed. I used Franks (754) no weld kit and it's done quite well on all my rides, I don't notice a difference in a similar bike with or without a frame kit that's fitted properly. The suspensions, now that's another story. 

I will probably end up getting the frame kit. Frank was sold out when all this happened so I just went ahead without it. It was a pita cleaning the cyl/head surface with the engine out. The grafite & copper coat was stuck pretty good. I can only imagine how long I would've spent on it inside the frame.

[JoeCooley]

Update: It runs again!!!! 😲

So it's all back together. Rebuilt F1 head with Kimble White springs, K2 cam, and MLS head gasket.... My 836cc 78K lives to fight another day.

[Desert-SOHC]

Thats great

[calj737]

...but I don't feel right about cutting a good frame and sacrificing frame rigidity. I ride pretty hard into turns when I'm in the mountains.

I see this sentiment posted often. As for the rigidity lost with a frame kit; poppycock! A mechanical joint (like Franks) can be just as strong as the continuous tube (stock). Plenty of modern bikes use 2 piece frames, bolted together with no loss of rigidity. Even modern bikes use bolted on subframes connecting the suspension to the main frame and engine mount with zero ill effect.

If you don't want to cut it because of stock, unaltered condition, so be it. But to believe you will be suffering stability or rigidity as a result, you are mistaken. Feel free to saw and install a welded or weedless kit at your convenience.

[rickmoore24]

...but I don't feel right about cutting a good frame and sacrificing frame rigidity. I ride pretty hard into turns when I'm in the mountains.

I see this sentiment posted often. As for the rigidity lost with a frame kit; poppycock! A mechanical joint (like Franks) can be just as strong as the continuous tube (stock). Plenty of modern bikes use 2 piece frames, bolted together with no loss of rigidity. Even modern bikes use bolted on subframes connecting the suspension to the main frame and engine mount with zero ill effect.

If you don't want to cut it because of stock, unaltered condition, so be it. But to believe you will be suffering stability or rigidity as a result, you are mistaken. Feel free to saw and install a welded or weedless kit at your convenience.

+1 on that.

[SOHC4 Cafe Racer Fan]

...but I don't feel right about cutting a good frame and sacrificing frame rigidity. I ride pretty hard into turns when I'm in the mountains.

I see this sentiment posted often. As for the rigidity lost with a frame kit; poppycock! A mechanical joint (like Franks) can be just as strong as the continuous tube (stock). Plenty of modern bikes use 2 piece frames, bolted together with no loss of rigidity. Even modern bikes use bolted on subframes connecting the suspension to the main frame and engine mount with zero ill effect.

If you don't want to cut it because of stock, unaltered condition, so be it. But to believe you will be suffering stability or rigidity as a result, you are mistaken. Feel free to saw and install a welded or weedless kit at your convenience.

+1 on that.

Yep!

[JoeCooley]

Thanks for the advice guys. 👍

[JoeCooley]

A couple pics I forgot to add. I dropped the pan and cleaned out the pump screen and pan. Mostly just fine metal from the cam and some bits of black stuff from chain adjusters. The wheel on the primary adjuster was a little worn but didn't look terrible. There was a little thin piece of steel in the pan. Looked to be the end of a feeler gauge. You can see it laying on the drain plug. Kinda odd.

[JoeCooley]

The pump screenhad clumps of hair and fibers. I'm guessing from Blue shop towels. I guess I won't be using those again to wipe off parts... 🤔

[MRieck]

The pump screenhad clumps of hair and fibers. I'm guessing from Blue shop towels. I guess I won't be using those again to wipe off parts... 🤔

 Yes! Years ago there was an article in Road Racing World about a guy that was meticulous about his maintenance but always covered the opened up engine with red shop rags. Also cleaned parts with them. The end result after years was the oil pump screen became clogged and that was it. The fibers in those red/blue shop rags do not break down and are the perfect size to collect and pack up.
 I stopped using them for engine stuff and use the Scott's heavy duty paper towels the pull out of the box, Also blue shop paper towels. Blow off the parts with air too before assembly.

[JoeCooley]

Update: I finally got a chance to install a better exhaust on my bike. Me and Ted (ricky_racer) did a little trade for a slightly used Kerker header. I picked up an 18" cone engineering "quiet-er" core muffler. Its definitely not a quite bike. The exhaust turned out great and sounds amazing with the cone engineering muffler. You really helped me out on this one. Thanks again Ted! 

[JoeCooley]

Here's a quick video of the new exhaust.

It's still running rich. I think I need to move the clip position up a groove. The bike runs ok, but I can tell it's pretty rich. I also need to change the oil again and rebuild the oil pump. Noticed today that I only get 20psi of oil pressure when the bike is fully warm. I dont want to scrap another cam and valves.

Maybe you guys can provide some input. Why would the engine run super rich with the same carb tune as before the big bore? Wouldn't the bigger bore, fresh rings, rebuilt head, and good compression cause the bike to make more power and need more fuel?