Quote from: DoD#i on August 18, 2008, 07:07:52 PM
For future reference, take the caliper off before taking the fork out of the triple. Taking it off before you take the wheel out is not strictly needed, but makes that a whole lot easier, too.

I used something like a short chunk of 2x4 to give the 8mm Allen wrench a smack to get those caliper mounting bolts started coming off. A relatively gentle impact.

Yeah originally I planned on painting the caliper and fork as one piece but decided against it just for ease of painting.  Unfortunately I have it all taken apart already and have to figure out how to get it seperated now.

Quote from: qwertydude on August 18, 2008, 07:59:27 PM
Adding to this impossibly long post. Is that a king's rear tire? It could be a Dunlop GT501 which the kings is a clone of, but if it's kings 140/70-17 then yay! Someone else with this cheapo tire. Not the greatest but is good for it's 50-60 dollar price tag, and long lasting 10,000 miles on my last one. Hard to mount and took 3 ounces to balance but hey can't beat the price 

I have no clue what tire it is, the previous owner put it on and I haven't paid any attention to it what-so-ever.  I'll look tonight if I remember and let you know!

Quote from: pronator on August 18, 2008, 08:32:34 PM
I'm not sure from the pic but it looks like you painted primer on the entire rear shock? I don't know much about suspension but I don't think the chrome bar on that shock is supposed to be painted. Just a heads up. 

The rebuild looks like it's coming along really well though. Great job! 

I actually taped off the chrome bar that slides internally with the shock so you do see paint but its on tape    but thanks for looking out!

I wasn't able to get much work in over the weekend due to a company camping trip, but I was able to fit in the first of 2 grills to cover the big open spot created by the new tail section.  Sorry for the shitty pictures!










Thanks,

Nick

wow progress looks really good, looks unique n all. cant wait to see it finished

Thanks for the input!  I wish it would just move a little quicker but it seems life has to step in and put it on a slower pace than I would like.  As always as I get more progress done I will post up an update!

Thanks,

Nick

Would you be interested in selling the side covers off your old rear frame? I have one that was poorly repaired and I think it would be easier to get new ones. BTW I can't wait to see your bike finished. Great Job

I would be open to selling them for the right prices.  PM me an offer and we can take it from there.

Thanks,

Nick

Wow, just realized it has been almost a month since I have updated this posting!  Life has really gotten hectic lately and work has taken up a lot of time that would have been spent on the bike.  Working in sales with a down economy can put a damper on any project.  I don't have any updated pics to add but I do have everything painted except the tank, and about 75% of everything clear coated.  I'm hoping this weekend I can finish the clear coat and slowly start putting the engine back together before thanksgiving.

I'll keep this updated as best I can but not sure when I'll make the next update.

Thanks,

Nick

Man I have really been slacking on the updating the project part.  Still no excuse, life has just been hectic on all counts!  Planning a wedding, work, and life has gotten in the way but I finally got around to some pics of the project over Thanksgiving weekend!  As you'll see, everything is painted and ready to get reassembled:
























I still need to get the engine back together but thought I'd clear up some space in the garage by at least getting it back together.  Also trying to locate a complete and unmolested wiring harness because the one I have is a complete piece of crap!  Engine, and wiring harness should be the last two hurdles before getting it all completely back together!

Thanks for still looking, hopefully I'll be able to update a little more.

Nick

Looks like you've been going at this for a while.

Congrats on keeping the project going and not giving up!

Wouldn't be nearly as long if I didn't wait 2 months for any major changes!  But its slowly getting there!

Thanks!

Nick

So I was finally able to secure some time/funds/energy to move forward with the bike.  Over the last 2 weeks I've slowly been piecing the engine back together in hopes of having it back in the bike before January.  I missed my deadline by a day or two but here are the updates!

Here is the engine as it sat minus any covering I did to keep junk/dust/debris out of the cases:




Here is a shot at some of the new parts going in.  I replaced the cylinders with a known/verified good set and had it honed at the machine shop.  Here are the pistons cleaned up, pins, and clips:




Here is the cylinders put on with the pistons all set.  Wrist pins were probably the hardest thing in this job (considering I've never taken apart or put together anything with wrist pins) but it was easy once you got the hang of how to put them in:




Here is the engine after bolting the head on, timing chain still hasn't been set yet in this pic.  One word of advice, whatever it takes DO NOT let that chain fall in.  I didn't have a string to tie it up out of the way and lost the chain 3 times!!!  which meant I had to take it apart 3 times to get it back out!!!!!




Here the engine sits on its makeshift stand (10 dollar step stool from walmart!) while viewing through the frame.  I forgot how much of a pain this was to get OUT of the bike, now I'm reminded how hard this will be to get back IN the bike!  Another word of advice.....ASK FOR HELP AT THIS POINT.  I had no one nearby so I was stuck putting the engine in the frame ALONE!




AND HERE IT IS!!!!! BACK IN THE FRAME AND BOLTED IN!!!!!  You can see some of the damage to the paint from trying to fit it in, but that can be touched up no problems.











Next up is takling the wiring harness. I'll have to extend some wires and shorten others based of the new tail and locations to mount.  If anyone out there would be so kind as to take some pics for me of how the harness is ran through the frame and up into the headlight bucket I would greatly appreciate that!

Thanks for looking, comments are welcome!

Nick

Looks Great! Does it run yet?

Not yet, valve cover still needs to go on, gaskets all around, wire harness, carbs need cleaned/rebuilt and the HOPEFULLY it will be ready to run then!

Thanks,

Nick

heh good job!

i know how much a pain it is to get it out...

i just removed my engine not 2 hours ago...

and i can wait till i get to "TRY" to shoehorn a honda 750 block in there HAHAH!

Oh lord! Good luck with that!

Saw in another thread, your debating wheather or not to clean your carbs. You've already done much harder things all the way through this project. Carbs are pretty easy. Just read the tutorial on gstwin.com.

That's what I keep think but i've worked on engines before so it wasn't as scary! I've never messed with carbs so I couldn't even tell you parts or how they work! Besides the engine was broke, I couldn't have done more damage! Lol

Well a small update here.  Work on the bike has slowed down yet again but this time due to a double spiral fracture of my 5th metatarsal!







Which has resulted in me wearing this for the next couple weeks:






But I did spend some christmas money, and birthday money on some new parts this week:


New Brake/Clutch Levers:



New Exhaust Gaskets:



New Trail Tech Vapor:



New Trail Tech Vapor Indicator Lights:






Progress will be updated as any is made!

Thanks,

Nick

Quote

Wow, how to go about installing one of these!?

I just ordered it so I cant answer that question for you but I know that there has been a couple guys on the forum that have intalled them that would be able to help you.