Tachometer drive block-off

Today at work, Lou and I cleaned prepped and filled the tach drive fitting with Alumalloy.

Jetting Analysis w/ O2 Sensor and A.F.R. meter

When we rebuilt the carbs, we had installed drilled main jets and larger pilots because we were removing the airbox and installing a 4 into 1 exhaust.

The engine was obviously running very rich, which was proven by the O2 sensor and A.F.R. meter.  We replaced both coils after trying to clean a corroded connection on one of them, and the mixture was still very rich.

After a bunch of test runs with various jets and needle positions, Lou figured out that the needles from the rebuild kit were shaped wrong.  He had me swap the stock needles back in, which improved the mixture significantly.  Now on the lean side, we shimmed the needles with .56mm which helped, but not enough.  Re-jetting to stock mains and pilots with .63mm shim washers did the trick.  It's like a different motorcycle now!

Fitted with Lou's O2 sensor and A.F.R. meter

Lou's guitar string method for needle shimming

The guitar string keeps the needle loose under the slide clamp

Installed new intake boots and synchronized carbs

Today the bike got new intake boots from Z1 Enterprises and a carb sync performed by Lou.  I did not think there was enough time to sync the carbs, but Lou pulled out off quickly and we both made it to work on time.

This 33-year-old motorcycle deserves new rubber boots.

Available at Z1 Enterprises

Lou, calibrating the electronic sync tool that he designed and built

Compression check, etc...

Today Lou and I did a compression check and then I re-checked the fuel levels in the carburetor bowls.  We also re-checked the intakes for leaks and confirmed that they are still leaking.  I have a new set of intake boots from Z1 Enterprises which I will install very soon.

The engine passed the compression test with 177-195 psi in all four cylinders.  Number 1 had 195 psi and the rest were between 177 and 187, if my memory serves correctly.  Lou took his notes with when he left, probably because he was afraid they would get lost in my garage.

Carb 1

Carb 2

Carb 3

Carb 4

I used a lawnmower gas tank to run the engine for warming up prior to the compression check.

Cylinders 3 and 4 had a better intake seal and are badly carbon-fouled because our jetting is too rich.

Top clamp modification

This should have been done shortly after installing the clip-on bars.  My friend Lou has done four of these over the years; make that five!  He filled in the holes by MIG welding them but a welder recommended JB Weld to me and that is what I used.  Time will tell if that was good or bad advice...

Lou in action with the hack saw

Hacked

Just prior to soda-blasting

After soda-blasting

Curing in the shed after painting