Could you give me a material list for this upgrade? I think I have referenced all the gaskets, cams, piston, rings, etc. But I want to make sure I didn't miss anything....THX!!!!!
Ferracci Piston kit - it includes rings, clips and new wrist pin
Stage-1 Husky cam Ferracci PN: F40600
Gaskets: head, base, waterpump
New copper crush washers for oil hose fitting
Locktite or liquid gasket maker to seal the rocker arm housing.
The shop manual
Piston ring compressor
A bearing puller might make life easier when pulling the cam bearings
A few things I learned from this ...
Remember to look at the decompressor before and after you install the new cam, make sure the pin retracts flush (or below) the shaft when it is fully open (weight all the way out). Mine didn't and I had to file it - not sure if this was a defect but I plan to ask Ferracci about this. Has anyone else had the problem with this cam? If you do modify the dempressor be very careful because if you remove too much material the pin (bump) will not protrude enough and you won't be able to start your bike because of too much compression.
Also make sure you never lose true TDC when you do the job, since there are no marks that distinguish true TDC from the top of the exhaust stroke - If you forget where it is there is a 50% chance you're timing will be 180 out. I found out the hard way ...
I think the manual says to tighten the oil union pipe (braided oil hose) fittings to 14.5lbs I'm pretty sure if you do this you will strip the head or case and be in a world of hurt. Just use new copper washers and go a little bit past snug and they should be fine. It's better to be too loose than to strip your case.
You will need a piston ring compressing tool - I can't imagine doing it without it. Most automotive ones are too tall and won't fit, so use one that's designed for motors with removable jugs. This was something I overlooked since I am used to rebuilding two strokes where you can use your fingers. This is a two person job.
Go slow. Everything comes apart without to much effort, so if you are forcing something excessively you probably missed a bolt. The head and rocker arm cover are over-engineered and there are bolts of all kinds in all places holding them together.
Post a report on the work and the results. Have fun!