Subject:RE: Constipation Date:Mon Oct 21 00:02:01 2013
Response to:18863
Amazing that it could be that restricted. Might be interesting to start it
without the muffler to see if it still pukes out oil. Of course, getting all of the
carbon out of the ports and exhaust would be best.

The owner's manual says that you should de-carbonize every 5000 miles or
sooner. But most people never bothered, and ran the bike until it stopped
running. 50 years later, you inherit a bike that is totally constipated...

The first thing to do is to remove the muffler. First, measure how much the
back end of the center tube protrudes from the outer body of the muffler, so
you can reassemble it the same amount.

The muffler's probably been attached to the exhaust pipe for 50 years, so it
might be easier to take off the muffler and pipe together, go outside in the
grass, and separate the muffler from the tailpipe there.

Put a 2x4 on the ground, and whack the back end of the muffler on it - this
will drive the center tube out of the front of the muffler body. The center
tube has about 100 holes in it. Undoubtedly, some or most of them will be
plugged up with carbon. Take a Phillips screwdriver or similar, and clean
them all out. Do what you can to clean the inside and outside of the center
tube (yes, there's a baffle in the middle of it), and the inside of the muffler
body. It's a dirty rotten - but necessary - job.

Stick your finger into the exhaust port. The port gets smaller - the actual
hole in the cylinder wall is a much smaller rectangular opening. You should
be able to poke your finger into the cylinder. Try not to knock any carbon
loose during inspection - you don't want it to fall into the cylinder. You could
try removing the spark plug and shining a flashlight into the plug hole, then
looking into the exhaust port, but I'm not sure how successful that would

If the exhaust port is really clogged with carbon, you need to remove the
head, cylinder, and piston and give them a good cleaning. That gets rather
involved, so if the port isn't too bad, put the exhaust system back on and
see how the bike runs then.

With luck, it'll run much better, and you'll get some riding in before it gets
really cold out.

Sooner or later, you will need to remove the head, cylinder, and piston for
cleaning. This is not rocket science, you just need to follow the directions
and work slowly and methodically. It's NOT a one-afternoon job. The only
oddball tool you need is a snap-ring pliers to spread the piston pin lock
rings. Sounds like a job for those cold winter months.