So, after getting the new cam, rockers and valve springs installed and top end buttoned up, I took the opportunity to install the 8-disc clutch pack I purchased from
@gggGary. Didn't take many pics here, wasn't really too much to see.
Since I had the RH side open I figured I'd fix a nagging issue from last year and tighten the wishbone spring on the starter gear. While I did replace this last year, and pre-tightened the replacement spring, I don't think I did a great job and would get the occasional garbage disposal sound when using the starter. I used
@toglhot's trick and slipped a 3mm piece of stock in the 'top' of the wishbone to ensure the clamping was directed towards the legs of the spring and not just overcompressing the 'top' bit.
I had posted a couple questions on this in various places including back in this thread earlier, but I was trying to figure out if I could use my original "Type C" tensioner. As many surmised - it didn't work great. (See pic below). The tensioner bolt can thread in just fine but it's just far too long and when threaded in to the recommended spec (end of rod flush with bolt) there is way too much of the assembly sticking out. While you could probably put some additional lock nuts on here to fill all the extra rod, I found a "Type E" on ebay for about $20 and grabbed it and a replacement acorn nut. This assembly works perfectly in the BBK kit. (Of course I didn't take any pics of the new one)
So motor ready for install, but a little detour. I had bought a new set of Vesrah pads for the front brake. Since I wanted to remove the rotor to give it a sanding prior to installing the pads, I decided to drill the rotor as well. I found some good threads on the forum and used one of the templates I found (word of warning - need to triple check the dimensions....for some reason they don't print to scale automatically, I don't know why). But in any case, I printed a template, used a center punch to mark the holes and then a 1/4" carbide bit, a little oil and a shitty Harbor Freight drill press to get it all done in about 90 minutes. It came out pretty good, although some of my holes were just slightly off. I realized this towards the end when my center punch got super dull and started to skid a little.
Pics of the process and rotor installed:
Back to the main event....at this point I reinstalled the front wheel, added a lot of protection wrapping to the frame, and carefully willed the motor back into the frame. I was a little worried this was going to be an awful process, especially since last time I laid the frame over the motor, but I was pleasantly surprised; it wasn't that bad.
Oh - probably should mention that my engine mount HW had started to show a little surface rust which was driving me nuts, so they went on a trip through the toaster-oven powder coater to get a bit of silver. Not perfect, but better than they were.
Now to try to get my new headers and Commando exhausts installed, along with the carbs, airboxes, etc. Worth noting that I took the carbs apart to clean them a few weeks back and double checked all the jets. Turns out my pilot and main were both off by one. Based on all that I've been reading about the 750 and carb tuning I knew I wasn't going to change much. I decided to just up the mains by one (to 130) and use the stock pilot.
At this point, last bit was to set the cam chain tension, set the valves per the WebCam spec sheet (0.005" exhausts, 0.004" intakes) and give everything a double check.
Took this video at 8pm last night:
That is a GREAT feeling when it first starts up....
.
FYI, I was purposely keeping the idle high as per the WebCam instructions (recommends no less than 2000 rpm for first 15-20 mins of operation).
So - 750BBK and new exhausts feeling like a success so far. Obviously the whole thing could still blow up (lol) but cautiously optimistic. I was very worried changing so many things at once but it runs and sounds pretty good so not a bad place to be starting from!
Few more pics with the side covers more or less fully together. Very happy with how the exhausts look (and sound) so far.