Project Indian
This page covers the progress of my Chief after taking it for a leisurely ride just before being torn down. I was going to take off the top end the next day to try and find a noise I was hearing that sounded like loose cam rollers. Couldn't find it in the cam chest or in the primary so was figuring it might be in the pistons. Boy was I wrong, never hesitate to take it off the road when you hear a noise that just isn't right. I got off lucky on this one in one regard, that it didn't take out the crankcased when it broke.  I was about ten miles from where I was headed when the bike dropped a cylinder and pulled onto the shoulder. I was able to start it right back up but only ran on one cylinder. I felt it might be pushrod adjustment and had my wife tow my into town with our sidecar. After returning home and disassembly I found out it was a busted connecting rod and a grooved crankpin. Let the pictures tell the story!!
This show what is left of the rod once the halves parted company. This is about one inch below the wrist pin hole. any lower and it would have went out the front of the crankcase.
This gives an idea of the rods wearing on the cases after they parted company. Several small cracks in the front and rear and rubbing on the halves also.
Shows the wrist pin still attached to the piston after the break.
The above photo was taken before the rod broke and illustrates the ignorance is bliss look on me!!  I am not making light of the situation, its just hard to believe so much damage existed with how well it was performing and little noise it really was making. Strong running and nice idle hid the problems well.
Page 2 of rebuild
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Bike Show 02