Idiots. The same guy that built the bottom end and used the right side main rollers to control crank end play had these intake nipples out.

The cast lip that surrounds the threads was chipped. Not sure if I should have someone attempt to weld it up or if the cure could be worse than the disease.

 

I believe the intent is for the seal to be where the nipple leading edge seats into the cylinder. Not where the flange of the nipple touches the cylinder.

That said, you are in for some fun.

 

I'll have to see how that would work out but if thats true its a little backwards on their part, in my opinion. Sealant would do the trick anyway and they hadn't yet put the pins in which complicated the idea of doing a pressure test.

 

Still put the sealant on all threads, just saying the chips in the location at the flange surface may not be a big issue for sealing. I hope for your sake.

 

The chips are in the outer casting that hides the edge of the threaded ring. Serves no other purpose but you see it and I dont like it especially on a restored bike.

 

Back focusing on this again. Had to get my 87 Suzuki off the lift first. Not a resto but a big refresh, engine is now an 1109 big bore kit so its even easier to kill oneself, paint job and correct some of the things that got changed over the years. These bikes suffered the same fate Harleys do. Cut this off, cut that off, lose the mirrors, signals, exhaust and so on. Some of the stuff is harder to find than old Harley parts.




Went backwards a bit. Pulled the oil tank to get the trans top cover off so I could flip the shift lever 180 degrees and pulled the kicker cover off because the kicker shaft must be bent. I can rotate it but it wont return with the spring. Just enough resistance the spring wont do it. Better now than when the bike is a running machine.

Then I can move forward and get the fenders on etc.

 

Jagged edge of the intake port is all fixed up. Had a friend look after it for me. Now I can finish the engine and put it in the frame.

 

Well done for sure.

 

That is a real good friend. Looks great. You correct the shift lever arm in the lid?

 

Not yet but the lid is sitting on my bench along with the kicker cover. Life has been getting in the way!