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Discussion Starter #1
This was/is supposed to be a cheap rider for me for this year, and maybe a real project next year. It remains to be seen if I can get her rideable on the cheap. If I can I’ve got some cosmetic changes I’ll be making too – even a rat needs a little personality.

I’m without a camera right now, so these are some the ebay pics of my purchase.
(if I can figure out how to use this thing)

If any of you saw this on ebay then you know I paid too much – the weather got warm and I got antsy.
[attachment=4:zdo2xxqu]400sm.jpg[/attachment:zdo2xxqu]
[attachment=3:zdo2xxqu]400sm1.jpg[/attachment:zdo2xxqu]
[attachment=2:zdo2xxqu]400sm3.jpg[/attachment:zdo2xxqu]


And these are insperation for this project
[attachment=1:zdo2xxqu]bikepics-1500851-full.jpg[/attachment:zdo2xxqu]
[attachment=0:zdo2xxqu]IMG_0726.jpg[/attachment:zdo2xxqu]
 

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Discussion Starter #2
Ok what to do with this thing (on the cheap) to give it a little personality. Some things to consider:

How do I plan on using (riding) it? – you know form follows function.
Daily rider to and from work, day trips, occasional overnight ride

Appearance wise what do I like about it and what don’t I like about it?
Dislike - that large instrument cluster, grab rail and protruding taillight.
Like – Wheels, shape of tank, side covers and frame, that being said I don’t think they look right for the bobber or cruiser look. I know it’s not nearly as desirable as the older models but I kind of like the looks of this engine type as well.

What’s damaged and can I make an appearance improvement while fixing it?
Spot or rear fender where chrome has flaked off, broken brackets that hold headlight, trust me there’s plenty more but these are the first couple things that come to mind.

What parts / accessories do I already have on hand?
I’ll get back to this.


Taking all this into consideration I have a kind of café-ish, sport touring kind of thing in mind.

I have a small chrome headlight and some stainless suitable for making the brackets so my first thoughts were to chuck the tach / speedo arrangement and run without them. But it is going to be a daily rider so I would kind of like to have a speedo. Then it dawned on me, don’t take ‘em off just hide ‘em. A café style fairing should do it, and I can put some repair straps on the broken brackets and it should hide those somewhat as well.

I’ve been riding Harley baggers for the past 20+ years, it’s going to need saddle bags. I’ve just grown too accustomed to them and I already have a pair of small leather bags. I think I can cut the loop off that grab rail and use part of it to mount the bags.

I’ve got some ideas for a lower profile tail light that will also cover the spot where the chrome is flaking off.

I picked up this fairing, no windscreen or brackets from http://stores.ebay.com/gardenstatecycles for $25 including shipping. I already have a lower set of handle bars that should work with it and I’m making the windscreen from the one that originally came on my FLHT.[attachment=1:q00394o3]fairingfrt.jpg[/attachment:q00394o3][attachment=0:q00394o3]fairingside.jpg[/attachment:q00394o3]
 

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Discussion Starter #3
Mechanically I'm waiting on a set of air cut off valves. When I got the bike it ran but very poorly. I re-cleaned the carbs and set the float levels, someone had done them but rather poorly. They had also smeared silicone on the air cut off diaphragms. The valve cover gasket was leaking so I pulled it, re-torqued the head and set the valves. The gasket looked to be in pretty good shape so I just cleaned everything well and put a little aviation permatex on it.

I also see I'm going to need to do something with the exhaust.
[attachment=2:1wpgexfp]Picture 067.jpg[/attachment:1wpgexfp]

Can anyone tell me any particular quirks or common problems to look for on this bike. It has about 18000 miles on it.

I replaced the buckhorns with these bars I picked up a couple years ago at a swap meet for $10.
[attachment=4:1wpgexfp]Picture 030.jpg[/attachment:1wpgexfp]

Although they were only used for one season I've had these saddle bags laying around for 20 years - I think I'll put those to good use.
[attachment=3:1wpgexfp]Picture 046.jpg[/attachment:1wpgexfp]

I had to trim back the fairing to clear the bars. Heated, bent and roughly shaped a piece of lexan for the windscreen. (cut from the old windshield of my FLHT) My first attempt at that was a failure. I'll share that later.
[attachment=1:1wpgexfp]Picture 045.jpg[/attachment:1wpgexfp]

Rough idea of how those should look installed
[attachment=0:1wpgexfp]Picture 014.jpg[/attachment:1wpgexfp]


As I said before really tring to do this on the cheap, just trying to get it rideable and not looking to bad - from 50ft after dark.
 

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I am really digging what you have done thus far... It has the best elements of a 70's - early 80's cruiser. A little touch of a BMW vibe.
 

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Discussion Starter #5
Well the air cut off valves for my carbs finally came in, but she runs as rough as she did before. When I goosed it a little she popped and spit flame out of the right cylinder.

When I was adjusting the valves earlier I noticed the cam chain felt loose. I loosened the adjuster nut per instructions in a Clymer manual and the already present valve train noise got louder, that can’t be good.

(I scored a factory manual for .99 + shipping on ebay the other day, but it hasn’t arrived yet. Shipping was a little high but it still came out to a fair price total $15)

Confession time, this thing has below recommended compression levels. I don’t recall the exact number, in my mind it was bad but not horrible and darn near even side to side.

At any rate today at minimum I’m going to pull the head and see what I can see. I may go ahead and pull the engine and through it on the bench.

I hope to be picking up another near complete bike with much lower miles on it – thanks Bill. So engine wise, I probably won’t do much more than pull this one apart for a look see.

Ernie
 

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Discussion Starter #6
Well engines out, head and cylinder off, and nothing in the cam chain tensioner looks broken, save for some of the plastic(?) chipping off the front guide.

The chain has been running loose enough, long enough, to have worn into the case and cylinder some. There’s no real damage to either piece but that chain has had to have been loose for some time. Sorry no camera today, I’ve been borrowing my neighbors. I’m sure the chain is shot.

A visual inspection of cylinders and pistons doesn’t look to bad, I’ll have to see if I can find my inside mic – and then I’ll have to see if I can remember how to use it, it’s been years since I’ve used one.

With the low compression and the shot chain ($93 on bikebandit) I’m defiantly going to be better off checking out the engine from that other bike.

I guess some peripheral tinkering is in order until I can get the other bike, but there is plenty of that to do.
 

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Heated, bent and roughly shaped a piece of lexan for the windscreen. (cut from the old windshield of my FLHT) My first attempt at that was a failure. I'll share that later.
I know this is an older post. I am about to attempt my first replacement windshield. Its a full size windshield going on a handlebar fairing. similar to the harley style in appearance. Have any advise?
 
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