The Chopper Compendium

Checking out why the carb bowl is overflowing, and I need to recheck the float setting,,,, Pulled the carb off, not an easy task, but left the cable connected, as I did not want to disturb that setup..... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild538s_Aug2017.JPG It appears ...

I didn't try just tapping on the side of the carb bowl with a wrench, that might loosen up the float, then will try other things if that doesn't work...
And the gasket on the float bowl seems to not seal very well, the gas overflowed pretty freely....

Had a few minutes to go by the shop and mess with the throttle setup on the bike... Some modifications are required.... So I flipped the cable anchor screw upside down on the throttle lever.... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild536s_Aug2017.JPG I clears just barely, ...

Been awhile since I set up cables, found some ss cable the right size at a fishing supply house locally... Short version below, More Pix over HERE... Soldered fittings on the end of the cable... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild520s_Aug2017.JPG It went together nice...

I'm going to try to fit this glass bullet lens on this old tail light housing....

This is the short version, there's more pix HERE..... The E10 fuel did this in two days... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild507s_Aug2017.JPG But it cleaned up nicely... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild510s_Aug2017.JPG Starting to w...

Meanwhile, back to the carb.... Since I had sealed the float mounting screw with shellac, and later found that it deteriorated in E10 gasoline, I had to try to clean that up.... The top of the mounting screw.... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild504s_July2017.JPG Pul...

The Crankcase Breather... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild475s_may2017.JPG Put a 5/16" brass barbed 90 on the upper hose.... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild502s_July2017.JPG Looks a lot better now.... http://www.wheelsmaui.c...

Yeah, I thought I might have to make up something to fit that recess where the copper washer goes, got lucky with Napa, it only took the slightest amount of filing to get that ID to fit the 10 mm banjo bolt... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild501s_July2017.JPG I'm l...

Solved the front caliper leak....



Using an unusual left side timing port plug...




Lots More Pix Here...

Had a difficult time finding a 5/16" barbed brass insert 90 to straighten out that upper hose on the breather.... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/62PanRebuild475s_may2017.JPG Finally found this on Amazon dot com.... http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/b...

http://img.jpcycles.com/zoom/380-518_A.jpg found 'em listed at J&P Cycle Morris Magneto Black Single Fire Module $139,99 $125.00 (Gold Club) Although I have not fired up the bike yet, I did crank the motor through to make sure I had the right wire on the right cylinder, and I did have a nice ho...

Got a copper washer from my local Napa that might fill that recess on the caliper.
More later....

Gonna go in the direction of reducing the OD of a banjo bolt washer to fit in that countersunk area of the caliper. Have some more of those washers on order, should be here in a couple of days...

Dan, I got that single fire setup from Morris Mags. It should show up on their web pages... Looked for some brass or copper banjo bolt washers like these, but nothing locally available, would have to go mail order http://www.wheelsmaui.com/UserFiles/Image/62FLProject5/BanjoBolt10mm.jpg I've had good...