Bryan Ward's 2004 BHC repair records

[Bryan Ward]

Bryan Ward's 2004 Boss Hoss Records, serial # 094

2004 BHC-3 385 HP small block, 750 Quadrajet carb.
Ordered from factory, arrived Jan 2, 2004, no miles, new.

Accessories

Batwing faring with smoked lexan windshield.
Coolant recovery canister.
Chrome crash bars.
Kuryakyn mirrors.
Heated vest plug ins (2).
Wide passenger seat and backrest c/w parcel carrier.
Chrome dash inserts.
Clock and temperature gauges from http://www.clocks4bikes.com.
Right side mount licence plate holder, built by me.
Installed tank bolt paint savers.
Installed polished aluminum spark plug wire seperators.
Installed "383 Stroker" badges on wire seperators. Gift from Stu!!
Installed lower frame corner covers, chrome, engraved.
Installed chrome swingarm end caps.
Installed leather tool bag on top of forks under headlight.
Installed Boss Hoss gas caps. Gift from Barry!!
Installed lots of chrome bolt covers from Marv in Daytona 2009
Installed chromed V8 oil filler cap.

Paint

Airbrushed realistic flames on black, 8 different colors in the flames. Clearcoated.
Wag's artwork on rear fender (Balls in Hand).
Paint by http://www.paintdruid.com

Modifications

Removed and discarded factory fasteners for side covers and seat pan. Made up a new set (10) from bolts which we drilled and tapped.
Installed V8 style body fasteners (10).
Installed 160 degree thermostat.
Installed fan switch. Fan operation is manual only.
Installed Tri-Star signalstat for omission of standard tail/brake light.
Installed 400 Lb. rear springs.
Installed Nesco #7 torque converter.
Installed transmission temperature sender and gage.
Sent out swing arm pivot bolts to machine shop. Now have greasable swing arm bushings.
Installed manual choke.
Installed K&N filter with Xtreme top.
Had carb set up as per Carb Mike for higher elevations, too rich before, at 140,000KM.
Installed reserve Pingel fuel switch.
Removed upper belt gaurd, now garage art.
Had a jacking bracket made up and bolted under bike with 2 rear tranny mount bolts, used in conjunction with a lever type jack to lift rear of bike vertically. Raises rear tire 2 inches off floor.
Installed stainless steel rock screen on front of radiator.

Mods, Repairs and Upgrades, Winter 2005-2006 @ 57,000 KM

Repair rock chips and scratches on all paint, new clearcoat.
Install Edelbrock Nitrous Kit with polished 2 1/2 Lb. bottle. (100 shot)
Install Holley Blue fuel pump with regulator.
Install chromed lower air dam.
Install Crane Adjustable Vacuum Advance, timing adjusted accordingly
Major service: change all oils, change thermostat, change throttle cable, repack wheel bearings, grease swingarm bushings, change brake fluid, clean air filter, change fuel filter.
Install Blue Seas # 5029 fuse block.
Install 8 gauge wire between Alt & Starter and Fuse Block & Solenoid.
Changed Tri - Star XP module unnecessarily: problem was poor ground.
Installed additional transmission oil cooler below radiator.
Replaced spark plugs at 57,000 KM, gapped at 45 thou.

Repairs, Summer, 2006

All brake pads replaced at 63,000 KM.
New Kuryakyn handlebar grips at 63,000Km. Right one worn out from friction inside housing, not from lack of lube, pot metal I guess.
Original water pump failed. New style Jabsco water pump installed at 83,000 KM.

Mods, Repairs and Upgrades, Winter 2006-2007 @ 87,000 KM

Rebuild engine to 383 Stroker.
Install Mallory rev limiter.
Install 160 degree fail open thermostat.
Install new 34 tooth front pulley.
Install new drive belt.
Install slightly used (1690 miles) rear pulley.
Install new pulleys for alternator.
Install new alternator belt.
Changed fork oil.
Install new front seal on transmission.
Replaced second gear clutch pack. First gear pack like new.
Installed new sun gear reaction plate in transmission.
Installed new 1st gear clutch drum bushing.
Made change to 1st gear relief valve ball as per Tom Chadwell.
Increased pump pressure in transmission.

Repairs, Summer, 2007

Output shaft bearing failure in transmission. Replaced shaft, brass bushing, teflon seals and all bearings and races including adding Marv's HD ouput shaft main bearing, at 98,000 KM.

Mods, Repairs and Upgrades, Winter 2007-2008 @ 118,000 KM

Major service, no repairs or modifications.

Repairs, Summer, 2008

Installed new rear brake rotor with new pads at 121,000 KM.
Installed new MSD 8.5mm spark plug wires at 122,000 KM.
Installed locally machined crankshaft adapter for alternator pulley at 122,000 KM.
Installed used set of Sanderson headers bought from Grumpy.
Flexplate replaced, came loose, bike split required.
Found blown out intake manifold gasket at that time. Pulled engine to repair.
Installed new Holley Blue fuel pump. Last one made 50,000KM.
Removed entire NOS kit. Not needed anymore, sold.
Installed new ignition switch. Last one made 100,000 KM.
Removed Mallory rev limiter. POS Failed. Installed OEM module.

Mods, Repairs and Upgrades, Winter 2008-2009 @ 140,000 KM

Rebuilt engine due to assembly mistakes in the beginning. Replaced camshaft, all bearings, rings and gaskets.
Had Carb Mike rebuild carburetor.
Had welder make lower frame crossmember and water pump mounting plate removable.
Replaced lexan windshield due to cracks and scratches.
Replaced chrome fan due to peeling with new Chinese one from Ebay. Better chrome.
Removed chrome discs from rear drive pulley and painted it black. Looks OK.
Replaced battery.
Replaced swing arm bushings, slightly worn, but enough to make belt alignment difficult.
Replaced both front brake rotors. Just plain worn out. (New pads as well)

Repairs, Summer, 2009

Drive belt broke in La Crosse, replaced with new Carbon belt.
Installed aluminum plates under bolts for front fender mounting brackets. Fender is cracked.
Installed 32 tooth front pulley, bought from Wag slightly used.

Mods, Repairs and Upgrades, Winter 2009 - 2010 @ 162,000 KM = 100,000 Miles

Repaint bike with newer style realistic flames, http://www.paintdruid.com
Install new (old style) front fender. Original is cracked beyond repair.
Install new (new style) rear fender, just because I like it.
Had my welder weld in rear frame section gussets.
Replaced leaking lip seal in 2nd gear piston of transmission. 2nd was slipping a bit.
Major service front to back.
Replaced both front rotors (again) warped, likely because of dragging calipers.
Replaced all brake fluid.
Overhauled both front and rear calipers. No parts replaced, just cleaned up.

Repairs, Summer, 2010

Replaced pick up coil in distributor, broken wire on it, had to be towed home 10 miles.
Replaced speedometer (failed) and sender at 172,000 KM.

Mods, Repairs and Upgrades, Winter 2010 - 2011 @ 184,000 KM

Replaced both upper and lower neck bearings and races (Timken).
Major service.
Change back to 34 tooth front pulley.
Change to newer 80 tooth rear pulley now machined and polished.
Two new tires, (see below).
Installed newer fan blade (thanks Wildman).
Changed to 6-32 all thread to attach fan to radiator (thanks Adrian).
Replaced Holley Blue fuel pump. This is the 3rd one and the last one!!!!
Modified gas tank mounts for easier and quicker removal.

Repairs, Summer, 2011

3rd Holley Blue Fuel Pump made 2500 KM!!! Went back to a Carter at 186,500.
Erratic voltage. Disassembled alternator, cleaned with brake cleen, now works perfect.
Installed new swing arm bushings at 197,000 KM.
Installed new Lyndall Rear Brake Pads at 197,000 KM. (first set of Lyndalls)
New radiator, in Sturgis at 199,500 KM.

Mods, Repairs and Upgrades, Winter 2011 - 2012 @ 206,000 KM

Had bushing holes in swingarm rebuilt to make them round again.
Installed new bushings and bolts in swingarm, still greasable.
Major service.
Rebuilt fork tubes, new bushings, seals, everything.
Gave faring to Paul H., added Harley style windshield.

Repairs, Summer, 2012

Installed new Lyndall rear pads at 212,000 KM. Made 15,000 KM.
Installed new cap, rotor and spark plugs, AC Delco. Made 70,000 KM.
Front fender cracked, repaired with Kevlar inside.
Alternator went south in Lewiston, Idaho. Had to buy a new non-chrome one to get home.

Mods, Repairs and Upgrades, Winter 2012 - 2013 @ 226,000 KM

Replaced Torque Convertor. Installed new custom built Coan 3500 RPM stall. Nesco # 7 made 196,000 KM.
Replaced oil pan. The alternator wore a hole in it because belt was too short. Removable crossmember mod paid off.
Installed smaller, modern bullet style signal lights and LED bulbs. Difficult to see. Need something better.

Repairs, Summer, 2013

Virtually nothing. Just some minor maintenance.

Mods, Repairs and Upgrades, Winter 2013 - 2014 @ 243,000 KM (or 151,000 miles)

Two new tires, see below.
Paint refreshed by original painter, rock chips repaired, etc.
New MSD distributor, HEI style, curved, installed and timed by Pierre Guyon at Guyon Racing, also cap and rotor and spark plugs. Original was getting sloppy in the upper bushing.
New rear brake pads. Lyndall pads made 22,000 KM. Very impressive.
New front brake pads. Appear to have made 68,000 KM??? Will try to verify, seems like a lot of KM.
New swing arm bushings, minor play in the old ones, seems to be an annual event.
Changed engine oil, Castrol GTX 10W30, Napa Gold 1069 Filter.
Changed transmission oil to 10W40 synthetic oil by High Performance Lubricants, David Ward's company.
General maintenance.

Repairs, Summer, 2014

New front Lyndall pads at 266,000 KM....last ones made 23,000 KM.
New rear Lyndall pads at 266,000 KM....last ones also made 23,000 KM.

Repairs, Summer, 2015

Split bike, replaced torque convertor seal and flexplate. Convertor bolts came loose.
Repaired signal lights and installed very bright LED rear lights. Now you can see me.
Repaired lower fork seal leak as per You Tube video. Great fix!!
New rear Lyndall pads at 281,000 KM. They made 15,000 KM.

Repairs, Summer, 2016

Replaced drive belt at 310,000 KM.
Major tune-up at 310,000 KM.
At 316,000 the frame broke near the neck on the right side. When it broke, it also broke and shorted the alternator wire (hot) and fried the entire wiring harness as well as the alternator and blew a hole in the battery. The cause was the lower left motor mount was broken but not noticed. Then the 2 upper mounts broke from the added stress and then finally the frame. I had Maritime Hydraulics in Moncton, New Brunswick, Canada do the repair. They did both sides, installed hollow sleeves inside the tubes, plug welded them and finally mig welded the breaks. Frame was also sand blasted, checked for additional cracks and powder coated. Lower motor mounts were repaired and reinforced, then powder coated. Also installed a new battery, alternator, wiring harness, master relay, valve cover gaskets, throttle cable, one new valve spring, all new roller rockers and upper radiator hose.

Repairs, Summer, 2017

Tune up required at 329,500 KM, new spark plugs, distributor cap and rotor. Found one bad wire which caused arcing inside the cap burning it up. All good now.

Warranty Repairs

Battery cracked and leaking from new, replaced with Napa product.
Radiator failure, replaced at 3,500 KM.
Transmission failure, rebuilt by Nesco at 30,000 KM. Installed #7 converter at that time.
Upgraded parts in front fork assembly (not sure what, noise is gone).
Swing arm replaced at 30,000 KM. Bushings were rotating in swing arm and not on bolts from new. Greasable bushings installed at that time.
Ignition switch failure, replaced at 20,000 KM.
Fan replaced due to peeling chrome, March 2006, peeled again in April.

Front Tires

(1) Avon Venom (factory) made 15,000 KM. OK, would buy another one.
(2) Metzler Marathon made 7,000 KM. Disappointing.
(3) Dunlop 402 made 15,000 KM. OK but cupped.
(4) Dunlop 402 made 15,000 KM. OK but cupped.
(5) Michelin Commander made 20,000 KM. Great handling, fantastic.
(6) Dunlop 402, made 19,000 KM. Cupped but not as bad as previous Dunlops.
(7) Michelin Commander 140/90 installed at 91,000 KM with balancing beads instead of wheel weights. Made 27,000 KM.
(8) Michelin Commander 140/90 installed at 118,000 KM with balancing beads. Made 34,000 KM.
(9) Michelin Commander 140/90 installed at 152,000 KM with balancing beads. Made 32,000 KM.
(10) Michelin Commander 140/90 installed at 184,000 KM with balancing beads. Made 32.000 KM.
(11) Michelin Commander II 140/90 installed at 212,000 KM with balancing beads, just wanted a new tire before Lacrosse trip.
(12) Michelin Commander II 140/90 installed at 243,000 KM with balancing beads. Still lots left at 31,000 KM, but cupped.
(13) Pirelli Night Dragon 140/90 installed at 266,000 with weights. Only made 19,000 KM. Wore out the left side of the tire only!!
(14) Michelin Commander II 140/90 installed at 285,000 KM with weights.
(15) Dunlop E3 150/80-16 71H installed at 305,000 KM with weights. Left side wore out.
(16) Pirelli Night Demon 150/80-16 71H installed at 323,600 KM with weights. Terrible tire, made 9,200 KM.
(17) Dunlop D404F 130/90-16 71H installed at 332,800 KM with weights.


Rear Tires

(1) Avon Roadrunner 230 X 60 X 15 (factory) made 18,000 KM.
(2) Avon 230 X 60 X 15 removed at 12,000 KM, now garage art.
(3) Michelin XGTH4 225 x 70 x 15 car tire, removed at 3,000 KM, too tall.
(4) Firestone SH30 225 x 60 x 15 car tire, too square, hated it, roasted it off at 10,000 KM.
(5) Pirelli P6000 225 x 60 x 15 currently, love it. Roasted it for 14,000 KM.
(6) Pirelli P6000 225 x 60 x 15 installed at 57,000 KM, made 18,000KM.
(7) Pirelli P6 225 x 60 x 15 installed at 75,000 KM, removed at 12,000 KM.
(8) Pirelli P6 225 X 60 X 15 installed at 87,000 KM. with balancing beads instead of wheel weights.
(9) Kuhmo 215 X 60 x 15 installed at 97,000 KM in SD. Only one available.
(10) Pirelli P6 225 X 60 X 15 installed at 118,000 KM. with balancing beads.
(11) Pirelli P6 225 X 60 X 15 installed at 140,000 KM. with weights.
(12) Federal SS 256 225 X 60 X 15 installed at 152,000 KM. with weights.
(13) Federal SS 256 225 X 60 X 15 installed at 165,000 KM. with weights, May 2010.
(14) Federal SS 656 (new model) 225 X 60 X 15 installed at 184,000 KM. with weights, Jan 2011.
(15) Federal SS 656 225 X 60 X 15 installed at 197,000 KM. with weights, Aug 1, 2011.
(16) Federal SS 656 225 X 60 X 15 installed at 206,000 KM. with beads, Feb 2012.
(17) Falken Sincera SN 211 225 X 60 X 15 installed at 222,000 KM with weights, Aug 2012.
(18) Falken Sincera SN 211 225 X 60 X 15 installed at 243,000 KM with balancing beads, winter, 2013-2014.
(19) Primewell PS 830, 225 X 60 X 15 installed at 255,000 KM with weights.
(20) Primewell PS 830, 225 X 60 X 15 installed at 266,000 KM with weights.
(21) Falken Sincera SN 211 225 X 60 X 15 installed at 281,000 KM with weights.
(22) Falken Sincera SN 211 225 X 60 X 15 installed at 289,000 KM with weights. Lots of burnouts on the last one.....
(23) Falken Sincera SN 211 225 X 60 X 15 installed at 300,000 KM with weights.
(24) Falken Sincera SN 211 225 X 60 X 15 installed at 315,000 KM with weights.
(25) Toyo Extensa A/S 225 X 60 X 15 installed at 329,500 KM. No weights required. Perfect tire!

Lubrication

MX4T Mobil 1 10W40 in the transmission until 80,000KM. Switched to PS-4 Polaris Synthetic as per Marv. No Mobil available at time. So far so good.
Transmission oil switched to Dexron ATF in April, 2007 at 89,000 KM.
Transmission oil switched back to MX4T at 98,000 KM.
Transmission oil switched to High Performance Lubricants, March, 2014 at 243,000 KM.

Mobil 1 5W30 Synthetic in the engine from 40,000-80,000KM. Now back to Pennzoil 20W50 organic to help reduce blow-by situation. This was caused by NOS damage resulting in a rebuild to a 383 Stroker.
New 383 Stroker will start with 10W30 Castrol GTX organic, April, 2007.
Switched to HP Lubricants Synthetic 5 W 30 USBP Long Life Engine Oil, June 7, 2014 at 246,500 KM.
Engine has 106,500 KM on it since the last rebuild.

Batteries

Battery replaced, first time at 96,000 KM, June 17, 2007.
Battery replaced second time at 140,000 KM, March, 2009
Battery replaced third time at 270,000 KM, May, 2015
Battery replaced fourth time (due to damage) at 305,000 KM, September, 2016

Wearing parts that are still original

Rear wheel bearings (regularly repacked)
Starter (never touched)
Both master cylinders (never touched)
Carburetor (except tune up parts from Carb Mike, Stage II, High Altitude)


Some dielectric grease.


More details pending

[Jack]

Excellent info in here. Quick question- why did you keep switching from weights to beads to weights again? Was a preference or availability thing?

[Bryan Ward]

I liked the idea of beads because there were no ugly external weights to ruin the appearance of the wheels. But I could never get them to balance well after 80 MPH. At 100 the bike was miserable to ride so I just went back to the weights.

[Jack]

Thanks, good to know.