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Steverino wrote:Until Loud Mouse and Hoosier Tom spotted the misassembly problems with my motor I thought it had never been apart.......Here is a picture of the starter chain misalignment due to the washer being placed between the filter and the case instead of the filter and the pin. Thanks for noticing that Hoosier Tom.

You're most welcome, Steve.

HT

Not sure about my friend Tom but he does know these engines/bikes.
I learned to look for things/parts which can be removed then installed wrong.
These engines are very simple mechanically but like any machine parts really need to be where they belong when the engine was issued.
I once knew a feller in Fort Worth, Texas who wouldn't let you know/watch him work on bikes because you might do the work and he wouldn't any $$$$$$$$$$$$$$.
I for sure and knowing Tom offer any knowledge to help anyone get these bikes on the road and enjoy as we have. .......................lm

Hoosier Tom wrote:

Steverino wrote:Until Loud Mouse and Hoosier Tom spotted the misassembly problems with my motor I thought it had never been apart.......Here is a picture of the starter chain misalignment due to the washer being placed between the filter and the case instead of the filter and the pin. Thanks for noticing that Hoosier Tom.

You're most welcome, Steve.

HT

This Stud probably fractured when I removed the cap nut. They were real tight. When I reinstalled them today I had the left one at about 5 or 10 foot pounds and it just separated. No pop or anything. I could be wrong but I think they are pressed in. Do I need to find another lower case?

KIMG0798 by Steve Steverinomeister, on Flickr

The studs at that location are threaded into the lower case.
You may reconsider using a cap nut there as you may top out the nut and a cover installs over that area. ............lm

Steverino wrote:This Stud probably fractured when I removed the cap nut. They were real tight. When I reinstalled them today I had the left one at about 5 or 10 foot pounds and it just separated. No pop or anything. I could be wrong but I think they are pressed in. Do I need to find another lower case?

KIMG0798 by Steve Steverinomeister, on Flickr

Okay
Thanks Loud Mouse
Will do. I don't know why there were cap nuts there. I was just putting it back the way I found it. I think I am going to wait until I get the case separated before I order the studs. If one broke more might break too.
Thanks Again.
Steve

Steve

LM is right. I would definitely replace both those studs as, with the nut tight on the studs, you will have just been applying torque to the stud rather than tensioning it (them) against the case.

On a similar note, I would just run a tap into the the M6 holes on the cam chain tensioner flange. They look a little clogged to me. On all those M6 holes I run a clearance drill into the holes to pull out any dirt then run in a bottoming tap (flat end) in to clean the thread.

G

Steverino wrote:Okay
Thanks Loud Mouse
Will do. I don't know why there were cap nuts there. I was just putting it back the way I found it. I think I am going to wait until I get the case separated before I order the studs. If one broke more might break too.
Thanks Again.
Steve

Thank you G Man
When I broke those cap nuts loose I was concerned because they were tight beyond any reasonable torque setting. Now that I know they were not put there at the factory I think they were fouled on the top of the studs. I am going to take a look at the inside those cap nuts. I will clean up those threads too.
Thank you.
Steve