Documenting the rebuild of my Pro Sport 107 - motor, exhaust, etc and some WTFs

Energy One
LA_Dog

LA_Dog

Go Fast, Go Faster
Brew said:
Well brother, I have to say! If you pulled your cam cover as you explained above, thats bound to happen! You have to shorten your push rods to relieve the pressure off the cam... Just saying...:confused:
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Thanks Brew- could you explain how that might have caused a failure after re-assembly? I got the info from S&S as the easy way to change out breather gears- looking at the cam lobes and lifters with the 5'oclock position on cam slot, everything is on the base circle except for two lifters, which are on the flats. the cover came off easily and went back on easily. The first time I took off the cover the bearing on the nose was already spun off, but I did not notice it since I wasn't sure what I was looking at, so it had failed even before I took the cover off the first time.
 
LA_Dog

LA_Dog

Go Fast, Go Faster
well i just got cam out and it appears the cam was not fitted with any end play. the spacer washer and the dog ear washer were pushed back into the case, this caused the dog ear washer to cup forward and it seized up with the spacer washer, the dog ear washer eventually cracked in half and the spacer washer started filing down and eating into the camshaft. So I can only assume that too thick of a spacer washer was put on, cam cover cranked down, drove the camshaft back solid with the washers, and no one checked if the cam had sufficient play. the cam nose bushing that is stuck on cam end is all the way flat with the gear.

The torrington bearing in the case looks ok but is sitting maybe 1/16th inward from flush- I don't know if that bearing should be flush or sit slightly inside of the hole.
 
Brew

Brew

Troop Supporter
It just makes no sense that the cam end play wasn't checked, thats so simple and I would think a competent mechanic would do this. Is the shop going to fix you up? Or, are they going to blame you for improper break-in or something like that and make you pay for this?
 
LA_Dog

LA_Dog

Go Fast, Go Faster
Yeh well there was a laundry list of things not put back together right. did I mention that the static motor timing was not even set correctly? It was left way ridiculously advanced. I don't think anyone bothered to set the Twin Tec module at TDC (which also is something simple). Even if say I was "hard" on the motor for break in, a cam would not just detonate like that on its own. They offered to either work on fixing it or refund my labor $. I opted for refund. I'm seriously thinking of just getting an Ultima 113 or 120 and calling it a day. Absolutely beautiful weekend weather and I'm stuck with no bike like a chump.
 
LA_Dog

LA_Dog

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here's something odd. the "spacer" used on the cam in front of the thrust washer looks like a regular washer that had been painted black. Aren't these supposed to be a machine bushing type of shim washer just like on Shovels?
 
LA_Dog

LA_Dog

Go Fast, Go Faster
update- i went through most of the motor and it all looks reasonably ok. no metal pieces anywhere else beyond some very fine sparklies. oil pump survived ok, a couple of light scores but very minor. the wrong pinion gear was definitely installed (white dot) with the red dot cam. white dot pinion is way too small.

rear lifter block had a goddamn hash mark on the inside end of lifter bore- looks like it was done with a screwdriver or something??? anyway, that hash mark made a flange of aluminum stick out and it was preventing me from removing the lifter from the tappet block. i spent 30 minutes with a razor blade nicking away at the hash mark and used some fine emery cloth to clean it up. fortunately it is not in an area that the lifter travels through other than removal. I mean, come on.. how does this happen?

Am putting everything back together Wednesday. T-Man was way cool and sold me a replacement 625 cam at discount. and I didn't even ask. very nice of them.
 
LA_Dog

LA_Dog

Go Fast, Go Faster
In the interim I decided to pick up another bike. a few pics attached. Came across a 2013 HD Breakout, has 600 miles on it and a lot of nice upgrades. custom House of Kolor gunmetal metallic paint, PM wheels / controls, Stage 1 Screaming Chicken upgrade, new Avons and some VH radius pipes. Also has some parts powdercoated black. the 103 is definitely a bit tame on power, but it rides nice and it runs.. LOL





 
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pknowles

pknowles

RETIRED
That is sharp looking. Only thing you need is to loose the reflectors and the orange blinker covers and get yourself a set of the smoked ones
 
francoblay1

francoblay1

The Spaniard
LA_Dog said:
In the interim I decided to pick up another bike. a few pics attached. Came across a 2013 HD Breakout, has 600 miles on it and a lot of nice upgrades. custom House of Kolor gunmetal metallic paint, PM wheels / controls, Stage 1 Screaming Chicken upgrade, new Avons and some VH radius pipes. Also has some parts powdercoated black. the 103 is definitely a bit tame on power, but it rides nice and it runs.. LOL





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Very f...g NICE!!!!! :2thumbs:

:cheers:
 
LA_Dog

LA_Dog

Go Fast, Go Faster
pknowles said:
That is sharp looking. Only thing you need is to loose the reflectors and the orange blinker covers and get yourself a set of the smoked ones
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Yup! all of the reflectors came off this morning, including the rear fender. was surprisingly easy to take them all off. next is swapping the blinkers, the factory ones are definitely ugly..

Also thinking better forward controls. I don't like the factory position- needs to be 2 inches forward. pegs scrape the ground too easy with their current position (did some peg scrapin' on my maiden ride home last night from the dealer.. good times :D

The VH pipes sound pretty mean. I don't know how they are for performance but they looks / sound nice.
 
RCAdd1ct

RCAdd1ct

JAFO
LA_Dog said:
In the interim I decided to pick up another bike. a few pics attached. Came across a 2013 HD Breakout, has 600 miles on it and a lot of nice upgrades. custom House of Kolor gunmetal metallic paint, PM wheels / controls, Stage 1 Screaming Chicken upgrade, new Avons and some VH radius pipes. Also has some parts powdercoated black. the 103 is definitely a bit tame on power, but it rides nice and it runs.. LOL





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That is how I ended up with a chopper. Main bike broken.
 
LA_Dog

LA_Dog

Go Fast, Go Faster
Hey what's up guys hope you are all getting some good riding time in. Yes, I've been absent.. busy riding the new HD scoot and having some fun. I was way long overdue.

So I got back to the Dog today and wrapped up putting in the lifters, pushrods and buttoning everything up. I bought "quickie" pushrods from SS so I did not have to pull the rockers. and guess what. I did so much decking / milling / sinking valves that the intake pushrods would not clear the tappet blocks by 2 stinking mm's. The exhaust pushrods had plenty of clearance. and yes I used the shorter rods for the intake.. lol.

So off came the rocker covers- pretty easy actually once I cut down an alan wrench shorter and loosened the tanks to hinge them up a bit. I loosened up the rocker arm bolts about 1/16" or so just enough to get that added clearance on the intake rods. I also checked my umbrella valves - looked good - the oil drainback holes do look a bit small so I might pop the rockers out this fall and drill them larger- that is, if this Dog is still running. heh.

Gonna fire her up tomorrow and see how it goes.
 
LA_Dog

LA_Dog

Go Fast, Go Faster
thanks bud- I guess the one main thing I learned out of all this is, you should always own at least two bikes. I see you have three :D
 
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