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Rear Cylinder

Posted in Engine, repair, The Long Rode on May 22nd, 2012 by Wade

Got the rear jug off.  its beautiful inside.  it is also .01 over bore.  I dont see a more size on the front piston.  They do seam to be a matching make of piston.  I’ve got a call in to a local (ish) machine shop, that comes highly recomended by Hawg, for a sleeving and boring to match out the cylinders.

 

Got a quote for the repairs to the cylinder.

  • $275.00 for Sleeving
  • $320.00 for pistons, rings, boring and labor
  • $650.00 for valve job.  Assuming parts are all good.
  • $50.00 for gaskets to put every thing back together
  • $1295.00 To put Marlin back on the road.

 

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Top end

Posted in Engine, repair, The Long Rode on May 21st, 2012 by Wade

I’m very depressed.  I got the front cylinder off tonight and found disaster.  There is a deep gouge in the cylinder wall and the piston id shot.  A C clip broke and scrubbed a lot of metal out of my engine.  You can see the broken clip here  and the damage here.  Don’t forget this is only the front cylinder.  It was the rear cylinder that had the compression issues in the past.

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Headless

Posted in Engine, repair, The Long Rode on May 21st, 2012 by Wade

I spent several hours today taking Marlin appart.  Unscrewed the headers, took off the carb, removed the tank, and seat.  One thing I noticed was oil in the intake manifold ports.  I then took off the front head.  5 bolts and and lot of swearing.  Since I dont know what I’m looking for I guess I’ll keep going.

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Tappets

Posted in Engine, The Long Rode on May 20th, 2012 by Wade

Last night I decided to drain the oil.  Then this morning I was going to refill and head up to the swap meet.  When I pulled the filleter out of the oil tank I noticed some particulate mater on the rim.  Upon further inspection it looks to be metal fillings.  SHIT!  Well long story short I talked to Hawg and based on the noise the push rods were making he figured it was at least one tappet going out.  So this after noon I started pulling them apart.  Now I’m no expert but I’m pretty sure the tappets are in good shape.  There is no play that I can tell in them.  So the next guess is maybe a piston is disintegrating.  Again SHIT.  But at least I’m checking all this be fore something catastrophic happens.

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Long ride

Posted in The Long Rode on May 19th, 2012 by Wade

I went on a long ride to Yuba City today.  It was over 100 miles round trip and the on the way up I was very pleased with how things went.  There were no problems and I enjoyed the ride.  Going home was another story all together.

When I pulled up to Hawgs house there was some noises coming from the front cylinder (exhaust lifter to be exact).  Hawg said “no bigie” its ether a dirty hydro lifter or the pressure regulator spring is going.  So we had a good conversation and I picked up the NOS master cylinder I went for.  It was now time to leave so I hoped on Marlin and took off.  Except it was a little rough to start and seemed to be touchy at idel.  But I rode off and got about two miles away when it died at a stop light.  Problem now was I couldn’t get him started.  So I called Hawg and he came to the rescue.

Based on what we heard when I arrived at Hawg’s he brought a new hydro and we changed it out on the side of the road there.  Problem now was that the battery was to dead to start the bike and it was stupid hot.  Another problem was that the circuit braker kept popping.  Worse we couldn’t find the stupid thing.  It wasn’t under the dash but rather under the rear fender (ethnic rigging) but it was a good thing we took off the dash because we found a shorted wire that later turned out to have no desirable use, at least according to the wiring diagram.  It’s still disconnected from the ignition and the bike runs just fine.  We finally got it started and got it back to Hawgs house were we started to check the carb.  It was loos and probably leaking.  So now the manifold is tight and the idel is turned up.  One the bike had cooled enugh I was able to hop on and ride home.  I had no problems until I ran out of gas and turned on the reserve.  Problem with that is there is no warning it just dies.  There is no warning that fuel is low.

Things to do.

  • Change oil trying straight 60wt oil.  Should fix the noisy lifters.
  • Check, clean, and replace the brushes in the gen.  It was only putting out 13 v
  • Rewire
  • Clean all the lifters
  • Replace solid core throttle cable with braided.
  • Tune the engine properly

Probably in that order.  But the ride was fun.

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Guards

Posted in Cosmetics, The Long Rode on May 18th, 2012 by Wade

About two week about I made what I think was a good find on ebay.  It was advertised as “late 60’s saddlebag guards.  The opening bid was good and so I bid.  At the end of the auction I was the only bidder and the rails were on there way.  The add siad that they would need to TLC and they did but not a whole lot.  One pad of 0000 steel wool and some crome polish and there as good as the rest of the chrome on Marlin.  I call these rails the “Starfish” type because of the backing plate that runs along the finder and I bought them because they have the same lights on them that the pictures on the shop manual have.  I think I did good.  Even if I didn’t I still like them and the starfish is the right stile for the bike.  They even fit around the bags.  Except now turn lights wont fit with the bags.

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Mounted Bags

Posted in Cosmetics, repair, The Long Rode on May 17th, 2012 by Wade

I just thought I would put a picture and a link to more of the bags after being bondoed, sanded and mounted.

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check off

Posted in The Long Rode on May 12th, 2012 by Wade

Things to do

  1. Change tires
  2. Change petcock
  3. Install rear turn lights (I have them)
  4. Rewire bike
  5. Refab the saddle bags. (mostly)
  6. Repair and Seal Gas Tanks

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Bag Reconstruction

Posted in Cosmetics, repair, The Long Rode on May 12th, 2012 by Wade

Today Paul and I tried to reconstruct my saddlebags.  It all started last week when I went out and got fiberglassing materials.  Cloth, mat, resin, brushes etc…  I watched lots of video and of course I’m not working on nice flat boat hules.  But away we went.  I first made some molds out of cardboard.  We had to get some different clay because the stuff I used first dried and cracked.

When we were satisfied with that I started cutting up the saddlebags.  I had two objectives.  One was to remove the big humps that were wasting half of the bag volume and two was to fill in the mounting and tail light holes since they were in the wrong locations and not wanted.
On the first bag we went whole hog and cut out the all the negative spaces of the bags and the holes.  Then I started cutting cloth and fiber to do the patching.  I did and inside and outside layer of the cloth and two layers of mat filler.  I hope that it’s thick enough.  Now it was time to open up the resin can but the lid would not come off.  I ended up having to brake the lid off witch pulled the neck out of the can.  So one way or another I was using the whole quart of resin.

Now the second bag was a bit different story.  We decided that we were just going to cut out the holes and not remove negative space since it was a lot bigger chunk of the bag.  Maybe I will attack that later after I see how all this turnes out.

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short ride

Posted in The Long Rode on May 10th, 2012 by Wade

I went for a short ride tonight after cleaning out the fuel filter, tareing the fuel filter and replacing the fuel filter.  I also adjusting the idel.  Once again the new tires were awesome very smooth ride.  But when I got home  Marlin dieseled and belched a big cloud of smoke from the carb.

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