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18-2-2017 X1 cylinder, XB big bore, XB problems

2-3-2017 - What did we do today: 18-2-2017 Buell X1 rear cylinder stripdown, BIGBORE Buell XB engine finish, Buell XB wont start.

we already stripped the front head off this X1 as the valve guides where leaking, but also spotted traces off oil before the valve , as the piston rings where not mounted correctly enough to make we want to inspect the rear cylinder — bij Twin Motorcycles Buell Support forever.

o yeas... nice and chewy...i wonder how they tightened it — bij Twin Motorcycles Buell Support forever.

old Torx key hammered in works — bij Twin Motorcycles Buell Support forever.

top cover off, remove the spacer ring — bij Twin Motorcycles Buell Support forever.

small bolts out first — bij Twin Motorcycles Buell Support forever.

and the 3 small hex bolts our — bij Twin Motorcycles Buell Support forever.

a nice oversized washers — bij Twin Motorcycles Buell Support forever.

evenly loosen the rocker box bolts — bij Twin Motorcycles Buell Support forever.

markings on the intake pushrod — bij Twin Motorcycles Buell Support forever.

mnnn looks like the tube has coused theme , will check for sharp edges — bij Twin Motorcycles Buell Support forever.

off with the heads — bij Twin Motorcycles Buell Support forever.

mnn very thick head gasket is used , i wonder why— bij Twin Motorcycles Buell Support forever.

the bolt story continues — bij Twin Motorcycles Buell Support forever.

to big washer and to long bolt — bij Twin Motorcycles Buell Support forever.

front intake even M8 metric — bij Twin Motorcycles Buell Support forever.

helicoil ? — bij Twin Motorcycles Buell Support forever.

piston pin rings out... best to not reuse these — bij Twin Motorcycles Buell Support forever.

2e comperssion is ring is upside down — bij Twin Motorcycles Buell Support forever.

and is bend open to much during mounting ? here looks ok — bij Twin Motorcycles Buell Support forever.

but halfway on the ring a hudge wear spot and — bij Twin Motorcycles Buell Support forever.

rear one , same story — bij Twin Motorcycles Buell Support forever.

and same on the rings wear — bij Twin Motorcycles Buell Support forever.

engine has only done 3000 km after rebuild HD dealer... really told the customer to go back to theme... and claim the crappy work , he rather had us make it good this time — bij Twin Motorcycles Buell Support forever.

good to clean the pistons... 0.020 OS — bij Twin Motorcycles Buell Support forever.

1e compression ring gap is ok — bij Twin Motorcycles Buell Support forever.

2e compression gap is to big ... so cylinders off for a light hone so the new rings will break in good — bij Twin Motorcycles Buell Support forever.

XB88 big bore valves back in the blacked out heads— bij Twin Motorcycles Buell Support forever.

grinding in the seats — bij Twin Motorcycles Buell Support forever.

clean very good after grinding in, valve seals in, put a drop off oil under the rings — bij Twin Motorcycles Buell Support forever.

and with spring compressor , the springs and keys back in — bij Twin Motorcycles Buell Support forever.

pushrod covers back on — bij Twin Motorcycles Buell Support forever.

bal end allen key is very nice here .. — bij Twin Motorcycles Buell Support forever.

pushrod cover O-rings first in the heads — bij Twin Motorcycles Buell Support forever.

checking if the headgasket is not toughing — bij Twin Motorcycles Buell Support forever.

now first the head over the pushrod covers, not to pinch the o-rings — bij Twin Motorcycles Buell Support forever.

than seat on the dowls — bij Twin Motorcycles Buell Support forever.

drop off oil on the head bolt flats and a little in the threads and tighten these to specs — bij Twin Motorcycles Buell Support forever.

push rods in — bij Twin Motorcycles Buell Support forever.

and mean and green rocker box on , trun in all screws to line up the gasket before you start tightening down the big bolts first — bij Twin Motorcycles Buell Support forever.

and top cover on — bij Twin Motorcycles Buell Support forever.

needed to assemble the rear one , — bij Twin Motorcycles Buell Support forever.

look for the notch to line up in the hole as flush as possible , not to scar the bolt shanks — bij Twin Motorcycles Buell Support forever.

and rear box on.. — bij Twin Motorcycles Buell Support forever.

tightening it down — bij Twin Motorcycles Buell Support forever.

if the gaskets not have been flat .. they have a will off there own , i drop off silicone will help theme to stay down and in place — bij Twin Motorcycles Buell Support forever.

nice .... :-) — bij Twin Motorcycles Buell Support forever.

next coil bracket and rear top mount — bij Twin Motorcycles Buell Support forever.

intake manifold back on — bij Twin Motorcycles Buell Support forever.

meeh some new heat shrink tube will fix this — bij Twin Motorcycles Buell Support forever.

mounting the oil lines — bij Twin Motorcycles Buell Support forever.

waiting on a bike to put it in ;-) — bij Twin Motorcycles Buell Support forever.

xb12s no start...customer had already tried to fix it , but something is still not right — bij Twin Motorcycles Buell Support forever.

neutral switch is out... we know — bij Twin Motorcycles Buell Support forever.

but should override with the clutch switch... but still no starter action — bij Twin Motorcycles Buell Support forever.

power to the start button. check — bij Twin Motorcycles Buell Support forever.

starter button works.. ( power at the other end ) check — bij Twin Motorcycles Buell Support forever.

ok fuses check .. all ok — bij Twin Motorcycles Buell Support forever.

relais .. start botton feed is there — bij Twin Motorcycles Buell Support forever.

easy to turn the fuse box upside down to have better acces to the wires .. — bij Twin Motorcycles Buell Support forever.

ground to diode in the fuse fox ? — bij Twin Motorcycles Buell Support forever.

diode check... put your meter on diode check .. one way it should let the test voltage through ( 0,5 volts for my meter ) ok — bij Twin Motorcycles Buell Support forever.

and the other way around it should black... check — bij Twin Motorcycles Buell Support forever.

ok the tan wire should have ground to let the start relais work.. little check if this works.. hot wire it to gound ... and she is starting.. ok defenaly the start inhibitor not working — bij Twin Motorcycles Buell Support forever.

ok first thing first... neutral switch as this is a intergral part off the starting system... cover off — bij Twin Motorcycles Buell Support forever.

we need to remove the belt off the pully.. so axle loose .. needed to take out the breaker bar to loosen the axle — bij Twin Motorcycles Buell Support forever.

give it about 15 turns out to loosen the belt — bij Twin Motorcycles Buell Support forever.

idler pulley bracket corroded on the studs — bij Twin Motorcycles Buell Support forever.

5 minuts wiggeling and penitrating spray the bracket cam off... bearings are toast btw ;-) — bij Twin Motorcycles Buell Support forever.

free the wires some to located the neutral switch wire — bij Twin Motorcycles Buell Support forever.

just checking... 7 K Ohm .. is not working — bij Twin Motorcycles Buell Support forever.

remove the belt off the front pully with a thin 5/8 socket you can remove the neutral switch — bij Twin Motorcycles Buell Support forever.

needs to go on a angle , but it works — bij Twin Motorcycles Buell Support forever.

look for the crush washer to come out — bij Twin Motorcycles Buell Support forever.

new switch in place , need to start it with your fingers — bij Twin Motorcycles Buell Support forever.

again just checking... 0.3ohm that is more like it — bij Twin Motorcycles Buell Support forever.

neutral working.. and engine starting — bij Twin Motorcycles Buell Support forever.

ok why douse the over ride clutch switch not work... could it be the wires are pinched under the handle bar ? — bij Twin Motorcycles Buell Support forever.

eeeh looks like it ;-) — bij Twin Motorcycles Buell Support forever.

pulled in out throught he flyscreen to have better acces — bij Twin Motorcycles Buell Support forever.

shrink solder joint... works very good — bij Twin Motorcycles Buell Support forever.

testing... yep you can start again with the bike in gear and pulling the clutch :-) — bij Twin Motorcycles Buell Support forever.

nice paint btw — bij Twin Motorcycles Buell Support forever.