Loud mouth '78

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Easter
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Loud mouth '78

#1

Post by Easter »

Actually it is pretty well mannered. I just have to get that noise toned down a bit. This has been a strange project from the beginning, I bought the bike for $75 only to realize the engine was locked up. After pulling the heads I found cylinder number 4 was full of rust and wouldn't allow the piston to cycle. Some sandpaper and a cylinder hone freed it up and it looked acceptable if not perfect. This was my first experience lapping the valves but thanks to a $5 valve spring tool found at a garage sale, and some coaching from a mechanic friend, I was able to get them into shape.

The reason the cylinder was rusty was because the bike had been parked outside for years with the shelter off and the breather box open. All the crud that ended up in the cylinder first passed through the carbs. So the carbs were a mess as well. Thanks to several rounds in my ultrasonic tank and a Randak kit, I got the carbs back into working condition. A new water pump was required but due to carelessness on my part the transmission cover had to come off three times before I got the leaks stopped. Then I blew a head gasket, yes, carelessness on my part again (plus a less than satisfactory gasket). The gasket was put on upside down and did not align properly with the oil return passage (I think it is) on the underside of the head. By now I am getting good at pulling the heads. Just not sure I trust my torque wrench when it comes to tightening that little bolt on the bottom to 10 lbs. of torque. I just know it is going to strip before the wrench "clicks".

Three months after I painted the wheels and installed the new tires and just as I was ready to wrap up the project, the rear tire went flat. Soapy water showed a leak all the way around the rim. The only sure way to avoid that again was a tube.

Well, this is getting long and boring even to me but I am just about finished with the bike now, a seat is on order, I have a set of Harley mufflers and I have a few more details like the idiot lights but it seems to run good, stop good and I think most if not all the leaks have been resolved. The cost of the project has grown from $75 to around $2000 but it has been another example of continuing education and for the most part a lot of fun. dancr
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Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
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desertrefugee
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Re: Loud mouth '78

#2

Post by desertrefugee »

Clean, utilitarian, purposeful. I like the 1200 fuel pump. Hmm. I have one in my box o' stuff. Where did you get the block off plate? That's a great idea...except losing the tach is something I think I'd miss.
- Life is not about waiting for the storms to pass. It's about learning to ride in the rain.
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Easter
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Re: Loud mouth '78

#3

Post by Easter »

I used the original insulator as a pattern and cut it out of a scrap of aluminum. If I were keeping the bike I might go with an electronic speedo tach combo. I plan to install the idiot lights in the head light bucket.
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
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Re: Loud mouth '78

#4

Post by duke182 »

Really looking good.
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Re: Loud mouth '78

#5

Post by handyman1018 »

Hi, very nice bike, pretty much exactly what I am heading to on my 81 rebuild. Do you know the source of the front fender?
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Re: Loud mouth '78

#6

Post by robin1731 »

handyman1018 wrote:Hi, very nice bike, pretty much exactly what I am heading to on my 81 rebuild. Do you know the source of the front fender?

Looks like it could be stock.

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Re: Loud mouth '78

#7

Post by Rat »

desertrefugee wrote:Clean, utilitarian, purposeful. I like the 1200 fuel pump. Hmm. I have one in my box o' stuff. Where did you get the block off plate? That's a great idea...except losing the tach is something I think I'd miss.
To quote the inestimable 'Fish' .... we don't need no steenkin tach .... just twist til it stops pulling then shift .... twist til it stops pulling then .....

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Re: Loud mouth '78

#8

Post by 230Rocket »

good looking bike, can I ask what color that is?

cheers
Dean
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Easter
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Re: Loud mouth '78

#9

Post by Easter »

230Rocket wrote:good looking bike, can I ask what color that is?

cheers
Dean
Sure, I will check out the paint code first chance I get. If I remember correctly, it is a late model Volkswagon color, something like "mountain mist". I have used it on three bikes so far--I like it.

Yes, those are stock fenders. Just rough up the chrome with 320 grit on a power sander. Then use a good etching primer. I haven't kept one long enough to see now it holds up long term but paint seems pretty well stuck to the chrome.
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
User avatar
Easter
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Re: Loud mouth '78

#10

Post by Easter »

When I get my seat, I will try to get some photos with a real camera. The wide angle lens on my phone makes it look squatty when viewed from the side.
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
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desertrefugee
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Re: Loud mouth '78

#11

Post by desertrefugee »

One thing's for sure - you'll be grinding down the tips of those pipes some...
- Life is not about waiting for the storms to pass. It's about learning to ride in the rain.
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Easter
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Re: Loud mouth '78

#12

Post by Easter »

desertrefugee wrote:One thing's for sure - you'll be grinding down the tips of those pipes some...
Not this old fogey! :crosso
Actually I have a set (3 sets) of Harley mufflers, just have to work out the adapters and hangers. For some reason, seem a little tougher on this bike than the others I have done.
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
User avatar
desertrefugee
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Posts: 3947
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Re: Loud mouth '78

#13

Post by desertrefugee »

On my '78, I didn't use an adapter at all. The ubiquitous Sportster mufflers slid right over the header. The stock muffler gasket proved too thick. I hacked a couple up trying to make them work and pretty much ruined them. Finally, I settled on some sort of fireproof tape a fellow at work had in his toolbox. Looks like a woven material of some sort. Sealed perfectly and keeps its shape after muffler removal. (i.e. re-usable).

So, with no extensions, the hangers ended up being very simple - just a couple of easy bends. I fashioned a couple out of 1/8" X 3/4" steel bar stock.
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- Life is not about waiting for the storms to pass. It's about learning to ride in the rain.
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Easter
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Re: Loud mouth '78

#14

Post by Easter »

I think these mufflers are actually Dyna mufflers, slightly longer than the sportster mufflers and have the slotted mounting strip on the back so the hanger will be a bit different. I had thought about the muffler repair tape, just haven't had a chance to look for it. But the center stand will have to come off unless I use some type of adapter on the muffler to header.
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
User avatar
Easter
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Posts: 2999
Joined: Thu Sep 13, 2012 11:33 am
Location: South of Houston 100 miles

Re: Loud mouth '78

#15

Post by Easter »

230Rocket, the paint is HONDA "forest mist" code: G53M, I used a base and clear combination.
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
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