Zero9243's Rebuild (New Pics 7/18/2011)

[zero9243]

So I don't really have any cool new pics or awesome progress, but the bike is pretty close to getting back together. Started running the wiring harness over the weekend, got the front fairing stay and gauge cluster on. I bought new cables for the ford coil pack and got that halfway wired up. I got the cooling system all hooked up and Modkings reservoir mounted which i'll get pics of soon. I bled the rear brake as well and hooked up the throttle cables.

Whats left to do now is clean the gas tank to get the rust out and finish the wiring, then I should be able to cross my fingers and fire it up!

[zero9243]

Coil pack is done, wiring harness is done, i put oil and coolant in the bike and checked for leaks, and there was one leak: where the 89 water pump housing mates with the metal coolant arm on the left side of the bike (if you're sitting on it). I had to order a new o-ring and got a couple of other OEM parts while i was at it. I also bought a couple of pipes to make the midpipe for my exhaust and got that powdercoated. I also put the new chain and front sprocket on and made mounts for my license plate and got that mounted up. Shame I couldn't get it to the point of trying to start it, but maybe next weekend...

[zero9243]

Pic of how it sits now. Crappy camera phone pic, but it'll do. All it needs is an o-ring, coolant, gas tank and a battery and she'll (hopefully) start.

[sweekster]

It's needs something....lemme think....lemme think....

Oh I know..

[zero9243]

She Started!!!!

[thatkid]

And I wish I had a picture of Dillon's face when it did. Priceless let me tell you.

[sweekster]

So how long did the "happy dance" ensue? Need a full update bubba....

[zero9243]

Initially top dead center was not set correctly, so nate and i had to pull the valve cover and re align the cams and it was actually a pain in the ass. but once that was done, i put the carbs on full choke and turned her over a few times and she fired right up! Let it run for about 10-15 seconds. she sounded good. Although the fact that top dead center was not set the right way in the first place makes me wonder if any of the valve stems got bent if i was unlucky enough that the valves were extended enough into the cylinder that they got hit. I'll have to take off the exhaust and carbs and check the valve stems to make sure i'm not screwed in that department

[zero9243]

I wish i had more fun pictures, but the look of the bike hasn't changed much lately. Got the fork lowers switched from the 89's to the 90+'s and got them all powdercoated, and then mounted the blue dot calipers to them. I ordered a goodridge SS brake line kit all around so i'll be installing those this coming week. I need to mount the exhaust and the front pegs and I should be ready to take her for a test drive!

[zero9243]

So I have an RK GB520GXW chain, but it is a Rivet type chain and doesn't come with a masterlink, you need a chain rivet tool to get the chain secured. A store near me has an RK 520 masterlink for $5, but since it's not a "GXW" masterlink, I'm afraid it will screw with the integrity of the chain, and become the weak point in an otherwise really nice chain

[thatkid]

I'm pretty sure the weak point is going to be the guy riding it. ZIIIIIINNNNNNGGGGGGG!!!!!

[shredex]

I'm pretty sure the weak point is going to be the guy riding it. ZIIIIIINNNNNNGGGGGGG!!!!!

[zero9243]

Well check me out! ADDING PICTURES FOR ONCE! Lots of progress, I'm very excited and anxious to get this baby back on the road.

Front view


Rear left view


Exhaust that still needs to be fully bolted on. I am planning on getting a tube bent in the future for a better angle and mate to the mounting point.


Flow Commander


Flow Commander remote mounting


Just for a quick reference, this is the relocation of my Voltage Regulator


Side view of the bike


Coolant reservoir and hydraulic clutch


Closeup of Hydraulic clutch


Hydraulic clutch lever, reservoir still needs to be mounted


Fresh fork rebuild with 10w fork oil, coated 90+ lowers, blue dot brakes and SS lines


The Hella headlight that Nate helped me pick out



And the Xenon kit I got for it


The masterlink in my chain that needs the rivets pressed


So that's it for now! Had a little trouble with the hydraulic clutch with the pushrod not being long enough, but that was solved and the clutch feels great. Now I just have to tinker with all the final settings and mounts and get the fairings done, but I'm pretty pumped how far she's made it!

[yamaha_george]

Hi,
Photoshop your rear number plate in the rear view picture or the bike might get a new owner before you want to part with it !

I also have an observation with regard to your VR mounting it looks to be isolated from the frame except for two allen screws as far as heat transference goes.

The original used the frame for extra heat conductance having felt mine after a 160 mile ride I am very much aware that the frame does get quite warm in that area. So it might be an idea to review that .

[thatkid]

Anyone with an airtech kit or just a crappy front light, this system is going to wow you so wait!

and those fork lowers look mmm, mmmm, sexy!