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29-3-2017 XB top end rebuild. prep for bored, hone

20-4-2017 - 29-3-2017 Buell XB12 top end rebuild. prepping for bored and honed cylinder

xb12 top end rebuild — bij Twin Motorcycles Buell Support forever.

mnnn loose stud.. the head gasket / head bolt was also loos , the reason the base gasket was sweating and head gasket leaking — bij Twin Motorcycles Buell Support forever.

counter nut on.. and remove the stud — bij Twin Motorcycles Buell Support forever.

threads look good .. — bij Twin Motorcycles Buell Support forever.

as far as i can see the threads in the case look also good.. so with some loctite — bij Twin Motorcycles Buell Support forever.

and tq it down.. feels good.. — bij Twin Motorcycles Buell Support forever.

so base gaskets on — bij Twin Motorcycles Buell Support forever.

cylinders cleaned in hot soapy watter to get all the hone debris out ... they are clean if you can rub your white shirt in there and the shirt stays white ;-)
beying so clean and degreased .. coat the cylinder walls right away with oil... other wise they will corrode very quicky — bij Twin Motorcycles Buell Support forever.

measuring the piston rings... these are to big — bij Twin Motorcycles Buell Support forever.

made to size and deburred .. 2e compression ring with dot facing up — bij Twin Motorcycles Buell Support forever.

with a piston ring clamp tool compress the rings and tap the piston in the cylinder — bij Twin Motorcycles Buell Support forever.

cylinder and piston to the engine , push the pin through the rod end — bij Twin Motorcycles Buell Support forever.

i screw the cylinder hand tight .. to prevent theme from banging around while mounting the other cylinder — bij Twin Motorcycles Buell Support forever.

bought cylinder on.. no first the pushrod covers — bij Twin Motorcycles Buell Support forever.

covers on.. ball end allenkey is very usefull for the rear screws — bij Twin Motorcycles Buell Support forever.

o-rings in the cylinder head.. with a coat off oil — bij Twin Motorcycles Buell Support forever.

locate the the orings over the pushrod tubes , than look for the dowels in the cylinder — bij Twin Motorcycles Buell Support forever.

using the frame openings to tighten the head bolts— bij Twin Motorcycles Buell Support forever.

bugger... this stud really douse not want to play nice.. i pull it out the case just over 25 ft/lbs dhammit — bij Twin Motorcycles Buell Support forever.

ok head off again, and protecting the lifters — bij Twin Motorcycles Buell Support forever.

ok head off again, and protecting the lifters — bij Twin Motorcycles Buell Support forever.

yup... problem found... ( the leaking gasket ) — bij Twin Motorcycles Buell Support forever.

i will repair this with a timesert . so need to dril and tap.. made a closed seal in the case hole with masking tape — bij Twin Motorcycles Buell Support forever.

nasty bugger — bij Twin Motorcycles Buell Support forever.

after drilling we need to mill the resess for the timesert — bij Twin Motorcycles Buell Support forever.

lube the mounting tool, i put some loctite on the insert — bij Twin Motorcycles Buell Support forever.

and stud back in — bij Twin Motorcycles Buell Support forever.

and she is holding — bij Twin Motorcycles Buell Support forever.

so mounting back the cylinder now the other way , with piston already mounted — bij Twin Motorcycles Buell Support forever.

head back on.. lube the head bolts base flats and in the threads and tq these in the steps given in the manual — bij Twin Motorcycles Buell Support forever.

when the markings are gone... the long pushrods are the exhaust ones ;-) — bij Twin Motorcycles Buell Support forever.

rocker box back on.. locate and start al the bolts before you tighten it — bij Twin Motorcycles Buell Support forever.

start tighening the bog bolts hold the rocker box even, and give the lifters time to bleed — bij Twin Motorcycles Buell Support forever.

cover back on — bij Twin Motorcycles Buell Support forever.

the rear , more off the same , but with the sensor wire in the center — bij Twin Motorcycles Buell Support forever.

little hard to get to all the bolts , — bij Twin Motorcycles Buell Support forever.

top tie rod mount back on — bij Twin Motorcycles Buell Support forever.

line up the coil bracket / manifold support — bij Twin Motorcycles Buell Support forever.

and header back on — bij Twin Motorcycles Buell Support forever.

intake in. with the 08 up i like to mount the bolt after i have put in the throttle bodie — bij Twin Motorcycles Buell Support forever.

injector wire ... universall buell .. green = rear , white = front — bij Twin Motorcycles Buell Support forever.

and some spark plugs in the easy way — bij Twin Motorcycles Buell Support forever.

i like to turn the plug cables in so there is little change off rubbing against the wire loom — bij Twin Motorcycles Buell Support forever.

engine up... bolt in place.. you should be able to turn this by hand , tighten the bolt to 66 Nm — bij Twin Motorcycles Buell Support forever.

w-brace back on.. nice bike it should all line up easy— bij Twin Motorcycles Buell Support forever.

left side the side stand and crank sensor connector in place ziptie it to the pipe — bij Twin Motorcycles Buell Support forever.

nice Torque Hammer 2 ehaust back on :-) — bij Twin Motorcycles Buell Support forever.

and mounting the belt tensioner — bij Twin Motorcycles Buell Support forever.

drained the cases.. so complete fill with break in oil , so we send the customer off with a good running engine — bij Twin Motorcycles Buell Support forever.

throttle wires on — bij Twin Motorcycles Buell Support forever.

the 08-up have nuts , easy to loosen the coil and slide it to the side — bij Twin Motorcycles Buell Support forever.

top tierod and ground point back on — bij Twin Motorcycles Buell Support forever.

ziptie the coil cables to the throttle cables ( has been rubbing ) .. coil not connected yet.. — bij Twin Motorcycles Buell Support forever.

fuel pump connector loose ... with a little airpressure in the oil tank.. first turn the engine over untill you have oil pressure — bij Twin Motorcycles Buell Support forever.

oil pressure is there.. connecting the fuel pump and coil — bij Twin Motorcycles Buell Support forever.

contact — bij Twin Motorcycles Buell Support forever.

it's alive.... ok for 10-15 seconds.. than shut it off to cool down — bij Twin Motorcycles Buell Support forever.

while the engine is cooling from first start... i prepair the next set ... — bij Twin Motorcycles Buell Support forever.

also cleaned in soapy watter — bij Twin Motorcycles Buell Support forever.

a few fingers off oil to coat the cylinder ( mounting and corrosion protection ) — bij Twin Motorcycles Buell Support forever.

oil rings usualy ok.. never hurts to check — bij Twin Motorcycles Buell Support forever.

oil rings the wafer ring first , than the 2 side scrapers — bij Twin Motorcycles Buell Support forever.

no marking on the 2e ring.. but you see a bevel on the inside — bij Twin Motorcycles Buell Support forever.

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

compression rings are squire , also gap is ok — bij Twin Motorcycles Buell Support forever.

so upside down... piston in the barrel — bij Twin Motorcycles Buell Support forever.

one side the piston pin lock ring in place — bij Twin Motorcycles Buell Support forever.

and pushing the piston pin half way in. ready to be mounted — bij Twin Motorcycles Buell Support forever.

check orientation and same to the other cylinder.. we can mount these to morrow — bij Twin Motorcycles Buell Support forever.

2e and 3e heat cycle.. each time a little longer.. to morrow last one and first test ride , before i put here on the dyno — bij Twin Motorcycles Buell Support forever.