[Yinzer]

Good choice of lubricants. The Mercury (Quicksilver?) was their straight GL-4, yes? Also, the clutch cable wasn't one of the OEM ones, was it? There are FAR robuster options. I like the Barnett one, but Hitchcocks offer various heavy duty ones.

I went with a recommendation here on most things. The Quicksilver Marine Lubricant may have been yours? [SAE 90 GL-4]
Originally, I was going to get Venhill cables but heard the ones from our host were equally good so I got all 4 Hitchcock's teflon lined ones.
Hitchcock's is also back in stock on the VM28 float valve so I picked up 2 of them today. [DHL knows me pretty well now]
The vent line was re-delivered to my house thanks to a nice homeowner down the block who was confused about it ending up on his porch.
Got tires, tubes & rim strip so I'll have plenty of stuff to do on day #4 of this project.

Nothing scary so far so fingers crossed

[Yinzer]

Day#4 progress...

Everything back together.
All new cables
Decompressor works perfectly & the old Magura throttle tube is smooth and returns without binding.
Clutch cable adjusted but unknown if correct.
New petcock, fuel filter, fuel & vapor lines, Tank cleaned and new cap cork.
Front brake cable installed but feels terrible. Rear brake feels pretty OK as is but will disassemble/clean/deglaze/lubricate anyway.

Only a few things to go...
Install K-70 tires, tubes & rim strip.
Adjust brakes [after doing some thread mining research]
Find bad ground in tail lamp.
Clean mayonnaise concentrator thingy???....Plug air filter box pipe inlet & make draft pipe exit to rear of bike.
Buy 2 gallons of ethanol-free gas.

I'll take some pictures next week. 

[Yinzer]

Day#5....

Got front tire, tube & rim strip on.
Thoroughly cleaned all the brake parts, lubricated & reassembled.
It doesn't appear there is enough material on the pads but they look new.
More lining would decrease the amount of travel making the adjustment easier & possibly improve the brakes???
Anyway...They seem to work for now. I might order new ones from H.

Drained the miniature oil separator where the duckbill thing lives and got about 1/4 cup of clean oil out. Fitted hose to rear of separator & blanked air cleaner.
It fired up on the 10th kick and filled the back yard w/ white smoke.
It cleaned up after I took off the choke but the RPM went way up and I had to kill it.
Tried a couple more times and same thing.
Slide looked all the way down but it apparently isn't??? (bleed screw & air screw adjustment had ZERO effect)
Ran out of time.

My guess is the new o-ring prevents me from screwing the top all the way down or I need to stretch the spring out??? [stronger spring?]
The adjustment cable lock nut on top is very thick also. Maybe I can find a thinner one.

Next up is new rear tire, tube, brakes, chain clean....etc.
Look for bad tail light ground.
Try to find carb fault.

The good news is it runs and the worm/quill seems to be sending oil up top.
 

[AzCal Retred]

The O-ring in the top of the carb slide tower caused my slide to hang up during a ride. I tossed it on the roadside, restored proper idle, no apparent ill effects with mixture. This isn't a hermetically sealed unit, there's no seal at the cable ferrule, any air leakage would have to leak past the cap threads anyway. Toss the O-ring and try it again.

[Yinzer]

Toss the O-ring and try it again.

Yep...I had a feeling when I was assembling it that something wasn't quite right when the cap didn't bottom out.
It just felt vague. There is a rubber thing to cover the cable adjustment ferrule but it looks more for show than functional.

I read the setup instructions about a zillion times and....?....Well....weird
I'm coming from to SUs, Zenith Strombergs & Webbers.
Bleed screw (little screw) out 1.5 to 1.25 turns and Air screw (big screw) all the way out so slide is fully down is the starting point.

My question is how does a quick turn of the accelerator briefly enrichen the fuel mixture rather than just open a huge hole?
There are no pump jets or oil filled pistons???
But hey...If it works it works. I'll figure it out later....Maybe

[Adrian II]

Nope, no accelerator pump on the Mikarb (which is a sort of licenced Mikuni copy). If you want a pumper carb, the Dell'Orto PHF range or some of the flat slide Mikunis (28 or 32mm, there's also a 36mm which is a bit too big for the iron barrel Bullet).

A.

[Yinzer]

Update time 

Bike is running and we went out for some diagnostic laps around the block.
Still have some issues.

1) Surging...
The chain was a bit loose so we thought that might be it.
Nope
Very noticeable cruising in 2nd gear.
Plug looks on the rich side of acceptable but maybe it is leaning out over 2000 RPMs???
Thinking about moving the needle up one notch (on center notch now)
(Everything bone stock now including all carb parts, exhaust & filter)

2) Questionable charging system
I'm going to look into that one & make myself more knowledgeable after doing some forum searches.
Disconnected headlight for some around the block riding and everything was OK for now but I have suspicions that something isn't right. (3 wire stator & stock R/R)

3) Front brake sucks...
Dad said it was my windmill to tilt because he doesn't care about it.
Ordering new pads from H and will try them.
Will report findings later.

Observations....
1) The clutch is pretty darn good.
Not Interceptor good but I have no issues with it.
During my searches, I read a lot about slipping and folks advising to shift to neutral for long lights.
I've held it in for minutes and it didn't get grabby or feel like anything was amiss.

2) The rear brake is suprisingly good.
I'm impressed. No reason to mess with anything there.

Things are coming along.
One thing to note.
It will only start w/ the enricher on. It prefers it on even when warm.

[AzCal Retred]

Yinzer - Looking Good!!

1) Mine started surging a bit when the air temps were cooler than summer. Raising the needle reduced it. There may be a better needle jet /needle combo out there. Possibly a float level issue. After you get the pilot jet sorted there is less need for the enrichener in warm weather. My alloy barrel machines need the enrichener more than the iron barrel units, they dissipate a lot more engine heat faster whilst shut down.

2) The OEM reg/rec on my Bullets tends to overcharge the battery. H's has a Lucas reg/rec and the Boyer Powerbox. My Boyer equipped unit regulates well. H's also has a 120W alternator set up.

3) The H's "sticky" pads work well. There is also some to be gained by careful set up. The Heavy Duty front brake cable is essential.

There is a pushpad assembly in the clutch that's metal-to-metal and doesn't get a lot of lube.
The "PART No. 90010 CLUTCH PAD/ROLLER, INDIAN MADE 4 SPEED" has a needle bearing, cheap insurance.
The primary chain can benefit from the "PART No. 200140 CHAIN TENSIONER BUFFER ASSEMBLY" also while you're in there.

[Yinzer]

I'm putting in another big order to H's (hopefully the last for awhile)
Long pipe & short bottle w/ db killer (to try)
2cm offset kick starter lever.
Clutch throw out bearing thing you recommended along with the rubber tipped primary chain tensioner.
New front brake pads w/ ridge

Got a Podtronics R/R in case I need it. (locally available and inexpensive)
Heading over to the "tasting room" tomorrow for some quality wrench time.

Weather is kind of iffy so we may not be riding.

Afterthought...
I should probably toss in a few more carb jets for good luck.

[AzCal Retred]

All my machines with the long head pipe can use the straight KS lever, it clears the header easily. Easy to make your own with a torch & stout vice. Heat to cherry red starting near the spline end of the shaft, bend until you are happy. There is a back bent further up to deal with also. I ended up putting a bit of filler weld on the "divot" RE created when they bent these, then grinding it back smooth. Paint makes us all look good, eh?
The straight lever can be positioned farther forward, giving more "swing" to the kick start process & providing greater ankle clearance on the foot peg.

[Ratz]

Cool picture! Thanx for posting 

[Yinzer]

Another couple of pictures.
It's running pretty well now.
I still want to arch the front brake but that is about it.

[Yinzer]

A good news update.
Dad passed his M test today at the DMV on the 1st try.
Evaluator said 88 might be an age record???

Bike is running great.
It's a 1 or 2 kicker & the plug looks about perfect.
He told me to stop fixing it and leave it alone 
I guess I have a tendency to do that 

[AzCal Retred]

Great work! Looking good, and a job well done. It's seldom we get to make someone that happy.

[Karl Childers]

The expression on your fathers face says it all! I'm sure he is proud to have a son like you.