Inspecting Alignment-Dowel Holes

The Nemesis 113ci and Patrick Racing 110ci big bore sleeves overlap the stud and dowel holes. In the photo to the right, the sleeve is the darker metal, and the cylinder is the lighter metal. You should test-fit the cylinder-top alignment-dowels to be sure they seat completely, are supported vertically and true, but are not displaced from their original position. Every machine shop and supplier makes little mistakes now and then.

If you build your engine without checking this, you just might end up like I did: with a huge oil leak from the head gasket, due to a misaligned cylinder dowel hole.

Supplier Selection

The best motorcycle suppliers offer more than just the products they sell. They also offer support, advice, and encouragement.

We depend on internet and mail-order suppliers for many motorcycle add-ons. And remote suppliers depend on internet and phone orders, to create a large enough marketplace to make their product costs pay off. Let's face it; if we had to depend on local suppliers for all our parts, we'd have drastically fewer choices for modifying our bikes.

It's true that using remote suppliers for after-the-sale-support does take more time than if everything can be done locally. But personally, I enjoyed this. I was in no huge hurry. I was enjoying working on my motorcycle, knowing that some of the most knowledgeable folks in the entire world (the Road Star world) were just a phone call away. This confidence and freedom allowed me to go beyond the homogenized, bolt-on, off-the-shelf mentality.

It's nearly impossible to guess how a supplier will treat you after they have all your money. You have to ask questions beforehand, and observe how they respond. But you should also ask the opinions of others that have used the suppliers you're considering. Forums and user reviews are great resources. Note: The Road Star Clinic website offers both. See the Forum tab and the Star Web Directory (on the Home page) for details.

Just remember to keep a perspective: The experiences of others reflect their opinions and values, and are very useful in that context. But they should not replace your own research and good judgment.

DK Montgomery (Powdercoater extraordinaire and Nemesis North American Distributor) with Author, right, (receiving newly powdercoated engine parts)

All the folks listed below not only helped with their product installs via email and phone calls; they also helped with all sorts of other question-and-answer sessions I had with every one of them:

• Nemesis Racing. Note: Nemesis Racing is no longer shipping products to the USA, so only the few products Nemesis manufactures in the US are still available to us. Greg Wicks was key in helping me build a power plant that still makes me grin every time I ride. He called me several times (from Australia) to help clear up complex issues--even when they had nothing to do with his products.

Most of all, he offered me self-reflecting questions so that I could come up with the exact motorcycle performance I was REALLY looking for. This turned out to be a very different engine than what some others were trying to sell me. He even remained supportive when some of my answers meant that I needed products from his competitors.

• DK Powder Coating (http://tidyville.roadstarclinic.com/dkcoatings.html). DK Montgomery helped me more consistently than anyone else. As North American distributor of Nemesis products, I expected him to help me with details specific to his products, but he talked me through every single aspect of this project. His passion for motorcycles, and work done properly, was obvious from day-one, and never diminished--ever. He even drove two hundred miles to ensure that a package got to me on time and in perfect condition.
• YamahaSportsCenter(.com, Taxarkana). I think these guys know more about our bikes than most, and they are willing to sit on the phone and discuss options and best-approaches. They are only slightly higher priced than Yamaha Sports Plaza of Seattle, and MUCH more knowledgeable.
• BulldogsCustomCycle(.com). David (Bulldog) Tise, and his wife Amy, were extremely helpful, too. David builds Road Star engines professionally, so his advise bolstered my confidence, and got me out of trouble several times.

Thanks to all these folks, and many others--online and off. I would never have attempted this project--nor completed it--without you.

Dedication: To my wife, Celia. She put up with parts everywhere, as well as being pretty much ignored by me for five months. Even when things seemed to be falling apart quicker than they were coming together, she never said anything negative (not one word). Thanks, honey.

To access related articles, refer back to the Complete Engine Tear Down, Orientation article in this series to see which additional articles best address your situation.

Questions should be asked in our forum (Use discuss link below). The forum is very active and you stand a good chance of getting your questions answered there. If you would like to leave feedback for the author, or have additional information you think will benefit others, please use the comment section at the bottom of this page.

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DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only.  Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure.  You assume all risks associated with the use of this information.  NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.  Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.

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