| Author | Message | ||
     Falloutnl |
As you've seen in the other thread, I've acquired an S1 Lightning back in August. Over the winter, I will be restoring it with the help of my dad and hopefully with some of the helpful input you fine folks are always so eager to provide (which is greatly appreciated). The bike ran, but after 8 or 9 years of standing still, it ran like dog shit. So the objective for the first weekend of wrenching (which was last weekend actually) was to clean out the tank and the carburetor to see if that cleared things up and to determine whether the engine sounded good enough to leave alone (other than the usual stuff). Some pictures:         As you can see, there was enough stuff to clear out. Regrettably, it didn't do that much to improve the way the S1 runs. It started up a whole lot easier, but afterwards, it still wouldn't idle properly and the amount of backfiring and flames spitting out of the air filter made it seem like it was on the verge of exploding. We didn't change the spark plugs though. Upon inspection those were thoroughly blacked out, so that might have something do with it. Not sure whether we're going to get to that this weekend. But I'll provide updates as the project progresses. | ||
| Akbuell |
Given the state of the carb/manifold seal, the manifold/head seals are going to be very suspect. I would plan now on including a date to replace those. And don't forget to make sure the accelerator system ( the little hole in the bottom of the float bowl and the brass tube sticking up) is clear. And congrats on your new machine. Hope this helps, Dave | ||
| Falloutnl |
Thanks! Think we put the compressor on that little hole in the bottom. And yeah, we'll check out those intake seals as well. | ||
| Williamscottrobertson |
I picked up another S1W, a lot worse shape cosmetically than yours and the transmission is bad. +1 on intake gaskets. A CVP deluxe carb kit goes a long way for $65. I’ve restored a few tubers. Do the exhaust hanger, bronze oil pump gear, Pull the primary and do the updated detent plate, updated primary tensioner, updated crank seal, and starter gasket. Put the one piece rocker box gaskets on if they haven’t been already. These bikes sit so long, then after a few heat cycles the seals/gaskets start leaking. A compression test wouldn’t hurt. My S2 with 15k miles had a burnt exhaust valve from what looked like a bad exhaust gasket. I found it when I pulled the heads for cylinder base gaskets lol. | ||
| Upthemaiden |
Couple things. When I got my S1, I think it took 3 carb cleans before it was actually running well, so dont rule out the carb yet. I've also heard cleaning carbs with compressed air isnt always good, because if something is clogged in one of the passageways, the air pressure can just jam it in further. If you do use it, make sure you always blow in the opposite direction that gas flows, to push things back out. Manifold gaskets are a good idea. Those right side bolts are a pain in the ass though, so be ready for those. | ||
| Falloutnl |
Yes, I think we have a cut down allen key for those bolts (from when we worked on an X1). Will look into that carb kit as well. Oil pump drive gear was on the to-do list, yep. Thanks guys. | ||
| Kmbuell |
William, do you have the part number for the revised shift detent? I’ve tried to order one from my local HD dealer with no luck. Kevin | ||
| Williamscottrobertson |
Hey kevin! I ordered one from my local HD for my Blast no problem. Detent Plate Upgrade HD Part Number 33656-90A + new retaining spring (11019). I often refer to don castos page for these things. http://www.doncasto.net/DonCastosS3ConventionalWis dom.html#Shifter%20Detent%20Plate | ||
| Kmbuell |
Thank you! | ||
| Firemanjim |
Did you clean all the carb jets and small passages? Slow jet is always a suspect as it is small and easily clogged!~ | ||
| Falloutnl |
I think we got 'em all, but like Upthemaiden said, it might take another good clean for it to really take. We'll know more once we have a day to work on the bike again. That'll probably be this Friday. | ||
| Upthemaiden |
My bike also had some rough running issues around 3krpm, right where I spent a lot of time. It was eventually solved by a couple washers under the needle. Not sure if the previous owner lost them the last time he rebuilt it, or if he just rode the bike like that all the time. | ||
| Oopezoo |
When I got my S1, it also had been sitting for quite a few years. I could get it to fire, but it ran like crap. It had a forcewinder intake and a Borla exahust. The carb was relatively clean inside, but still had the original jetting and the intake seals were all cracked and/or leaking. Once I buttoned everything up with new seals and got it jetted properly, it runs fantastic. I still have the suspension and cosmetic things to deal with , but it sure is a fun bike to ride. | ||
| Ratbuell |
Absolutely put new intake boots on. Dip a finger in engine oil and give the boots a good schmear before installation, to keep them from pinching or bunching during installation. Not "dripping with oil", but a good sheen so they don't stick to metal as you torque the screws. If you have access to an ultrasonic cleaner...put the disassembled carb in it. Pull your jets, pull your tube, pull the float needle, pull the slide, and let the ultrasonic do its work. An old finance manager I worked with had one that he used when he restored old Rupp minibikes. I'd take him a ziploc baggie full of carburetor parts (body, bowl, internals - everything, just fully disassembled). He'd toss it in when he got home and bring me a baggie of carburetor the next day that looked factory-new. If you don't have access to one...go to a hobby store and get a set of dental picks. Usually anyone who sells scale railroad stuff will have them, on a shelf near the x-acto knives. I keep a set in the garage, and I can't tell you how useful they are. Don't know how I had a workshop without them! And, they're great for poking crap out of jets. "8 or 9 years of standing still" - VERY similar to my S1W when I got it. PULL YOUR TRANSMISSION. I got my S1W running years ago, after I bought it, rode it for a day or so, then coming home...the rear wheel simply locked up. Inspection led me to a seized transmission output shaft bearing - years and years on the sidestand put that bearing "uphill" and let it dry out and rust. All-of-a-sudden usage made it seize up. Replace yours (or at least check it) before you have the same failure I did. (The good news when it happened to me was, it was an excuse to have the guys in the shop at work disassemble, back-cut, and micropolish my gearset...it shifts as smooth as my 1125!). | ||
| Falloutnl |
I still have the suspension and cosmetic things to deal with , but it sure is a fun bike to ride. Yeah, cosmetically this bike is o.k. but not spectacular. PULL YOUR TRANSMISSION. Yes, we will RB  . We'll inspect it at least. Suppose it's a good thing the older bikes have a trap door. When that bearing crapped out on the Ulysses, we have to strip the entire bike and split the cases. That bike is lucky I love it so much (and that my dad is a patient and skillful man). Absolutely put new intake boots on. It's on the list of things to do. For sure.} | ||
| Falloutnl |
Do I have picture and video for you. Check it out, the old intake-seals:  So yeah, that explained something. And after a bit more fiddling with the carburetor, the results were very promising: https://youtu.be/kbTJp8w7iG0 Merry Christmas everyone! | ||
| Mike_lee |
Congrats man. Nice ride | ||
| Screamer |
From the way the seal (in the photo) has pushed in to the manifold port, You might have a manifold that's slightly too narrow for the gap between the two heads. The excessive gap may expose too much of the seal - which could fail prematurely. On Sportsters and Buells in the late 90's, there were a few occurrences of the intake manifold that were incorrectly machined - making the manifold "too narrow". I wouldn't be concerned about it unless it fails again. If it does, fit the manifold without seals or clamps. The manifold ports should align with the front and rear head ports - and have minimal gap. | ||
| Falloutnl |
Will keep that in mind, thanks Screamer. Another update in pictures:     Bike is disassembled now. Piston pens were almost completely seized in the pistons. Rear cylinder wasn't torqued down properly for some reason. Have ordered a 1250 kit from Hammer Performance. They were on sale, making it a little easier to justify. Next steps are ordering all the stuff we need for the rebuild and cleaning up and painting the rusty brackets. Stay tuned :P Oh, something else. My dad's M2 tried to kill itself while we were working on the S1, it was on a trickle charger and some of the wires coming from the stator (or going to the battery?) started smoking and caught on fire, literally. Still can't believe how lucky we were that we were in the garage at that exact moment. | ||
| Phelan |
Those are James intake seals, which have a lip that fills the manifold gap and gets squished during installation. No doubt it was causing turbulence issues, but that particular seal is not pinched besides the lip. It could still have had a leak but it's not inherently that seal. | ||
| Mike_lee |
Id pull apart the oil pump and verify nothings broken inside as long as youre that deep into things. I forget the name of that gyro thing but it sometimes breaks. I planned on new pistons and honing the cylinders and decided to look into a 1250 kit but they had minimal piston options. It was a cyber week sale so the 1275 kit was like 50$ more. Of course i couldnt stop there...ugh! Happy the m2 is still alive  (Message edited by Mike lee on January 01, 2019) | ||
| Falloutnl |
Happy the m2 is still alive : ) Haha, we are too. Would've been a shame for a bike that pretty to go up in flames - not to mention the garage along with it. It was a cyber week sale so the 1275 kit was like 50$ more. Of course i couldnt stop there...ugh! So you ended up going with the 1275 kit? My dad decided to get a 1275 kit for the M2 as well now that we were getting stuff from the States anyway. Already dreading the import tax we're gonna get hit with, but it's still cheaper than buying them here. Honing the cylinders and buying new pistons would have been about as expensive as my 1250 kit (on sale). | ||
| Mike_lee |
yes, that could've been bad. good save. I did. after weighing options with the lack of piston available for the 1250, honing/new pistons and the sale, the 1275 seemed like a no-brainer. sent my heads in too for a valve job. only thing is, even though this bike will be ready for our trip to deals gap mid april, I doubt ill have the time to properly break it in as our winters here stretch til april anyway. I will most likely have to take the spare S1. Hammer is a pleasure to deal with too. I'm sure I tested their patience on more than one occasion. everything is installed on mine and she is now awaiting spring. this too was supposed to be a winter project but, I like to hurry up and wait haha I see you don't waste any time either. buy it and tear it down | ||
| Falloutnl |
I see you don't waste any time either. buy it and tear it down : ) On it! /edit: well, I do love riding these things, regardless of the scary amount of time we spend wrenching on them. Hope to get it done before the roads here are clear of salt. Hammer is a pleasure to deal with too. I'm sure I tested their patience on more than one occasion. Haha same here. Aaron has the patience of a saint. everything is installed on mine and she is now awaiting spring. this too was supposed to be a winter project but, I like to hurry up and wait haha Ahead of schedule, very nice. (Message edited by falloutnl on January 02, 2019) | ||
| Falloutnl |
Nothing much has happened since new year's. Got a message from Hammer Performance a few days ago that all the parts are boxed up and shipped out, but I think it'll take a couple of weeks for that stuff to arrive. In the meantime, I'll probably start cleaning up some of the parts we took off. Rockerbox covers, license plate holder and a few more items like that. | ||
| Mike_lee |
I took the day off to make sure i didnt miss my package when it arrived. Aint nobody stealin my shit hahah | ||
| Falloutnl |
Yeah, I've seen some of the videos lately. That would be a bummer with stuff this expensive. Not a problem we have in the Netherlands. Packages generally don't get left on the porch (our homes don't have any). Deliveries either have to be accepted by the recipient or their neighbours. In this case especially because the tax that is due on a shipment like this needs to be paid to the delivery person. | ||
| Falloutnl |
Yes! Way sooner than expected:  | ||
| Mike_lee |
Sweet! Installed yet? The break-in procedure....ugh! | ||
| Falloutnl |
No we just got 'em today, soon though! And the break-in procedure, yeah... that requires a lot of restraint  |
