Chillis rolls out of Vegas

Stupid responsibilities!

Looks like I screwed up.

While putting the clutch back together you have to align the outer pressure plate a certain way or you don't get full throw of the clutch.

I didn't notice this until I assembled it all and pulled the clutch lever to see how it felt. It went from firm to stop in almost no travel.

Put in gear to see if it is disengaging and nope.

Check some YouTube videos and sure enough I did not align on the proper groove. So I pulled it apart and am checking alignment and find the right place but yank the parts just to look and see what is what and the parts are so soft that I grooved some of the cast aluminum on those spring bosses.

Not only that, I also found pieces of aluminum in the basket. Out it comes and I ordered up a slipper clutch assembly which will replace the parts I abused during reassembly. Now the wait game.

I still have to install the big bore and the flywheel side parts so it isn't like I don't have stuff to work on.

Dodged a bullet too with the metal pieces in the clutch. Will wash all of that so I don't get a premature destruction of the engine.

Yikes

Not a big deal but it is annoying that a piece that can be put together 6 ways can only go together in 2 out of 6 and nothing shows you it is wrong until reassembled and it is locked almost solid.

what do you need for a plug for the O2 sensor port?

what thread is it?

i got a bunch of that kinda shit.

I was thinking more about the potential to pump fragments through the engine.

You'd think an index mark of some kind would've made it into the design. Might be worth making your own for easier work later on.

I didn't realize the bike had an O2 sensor because it wasn't on the stock exhaust. Big bore options require it for tuning so I ordered the exhaust with the bung.

Researched the stock bike again and saw they put the O2 sensor into the head protruding into the exhaust port.

Then facepalmed.

The plug will be here tomorrow. Thanks for the offer.

The slipper clutch on the way has an index for correct positioning.

Here is what I'm talking about:

Everything is very simple and straight forward.

Forgot to get razors for the base gasket removal so off we go.

Also, have to pull a bearing off of the cams, small end bearing, to swap over the automatic decompression assembly. Trying a half assed attempt of freezing both cams to see if the shrinkage(insert @KICKNBACK joke here) allows the bearing to pop off without getting a bearing puller. I don't have any sort of press or driver to reinstall. If it does not work I'll just install without and get a more powerful battery or HD starter.

Piston is in, head about to go on and then to see if I can do the auto decompression assembly switch.



I'll see if I can get everything done short of the oil cooler and clutch assembly since they go together.

A six pack might get that pressed for you today or tomorrow at a friendly shop.

Too late. That is all reassembled.

No interference, need to set valves, pull flywheel, replace tensioner, install new intake and hang oil cooler bracket/cooler.

you didnt re use the cam bearing did ya?

instant trash as soon as ya press on it or use a puller.

Nothing a long ride on the Harley won’t cure

it sucks happened but hopefully, the next guy watch this video

Negative, installed as is. Did not want to pull the bearing off. Getting a higher power battery for it to help cope. If it needs more I'll get the heavy duty starter.

I've gotten everything done short of the fuel injector, clutch/cover, and oil lines connected.

Fitment of chosen parts is excellent. I can't believe how good aftermarket parts have gotten. The Koso oil cooler kit and intake clear everything with nice packaging.

I could make a bracket for the MTake, a rectangular plate with 4 bolt holes and drop it a bit to clear the oil cooler bracket because they mount to the same holes.

I like the Koso intake better due to its smaller packaging which isn't pressing up against the throttle cables and the IAT sensor fits in a port into the silicone elbow of said intake.





The clutch pieces are scheduled to arrive Wednesday.

In the meantime I'll install the injector, flash my ecu, prep the clutch cover with fittings.

Really excited how everything fits together so well.

Anybody want the MNNTHBX intake, let me know. Nice power boost but loud if you do high speed riding a lot. My ears are still ringing right now from the Death Valley ride a few weeks back.

Question for the brain trust: I used the Lucas Assembly lube on the cylinder walls prior to piston install. Super tacky oil.

I know this will wreak havoc on start up due to higher compression.

Once it is all together and I can put oil in it my plan is to pop out the spark plug and crank the engine over for a bit with the socket on the end of the crank.

Anything else to be done to minimize possible damage due to the lube in the chamber?