I figured I'd start a new thread documenting the entire assembly process with pictures. This thread will be far from a proper assembly tutorial, and I'm sure it will illustrate some improper techniques and hardships, but hey, looking at pictures is cool....

Here the motor and areas of the frame are taped up, I also ground down the powder coating on the frame engine mount ears to aid in fit...





Here the motor is finally installed, hopefully it won't need to come out again, matter of fact, it WON'T be coming out again...





Tomorrow the Swingarm and Shock will be assembled and mounted, more pics to follow.

isn't it difficult to remove the blue tape after everything? Or do you take it off as you go along?

Quote from: ragecage23 on October 09, 2010, 10:52:52 AM
isn't it difficult to remove the blue tape after everything? Or do you take it off as you go along?

It can be, but I make sure the tape is in areas where it doesn't get pinched between the 2 items I'm trying to protect...Most of the tape will stay on until most of the assembly is finished, ya never know when your gonna drop, bang, or scratch something, so it's a bit of added insurance. Keep in mind though, this is far from a show bike quality, very far from that as my abilities, income, and impatiences just don't allow for it.

Well get with it would you!

Just curious, did you paint the motor with high temp paint? Until it's properly cured, it may come off in little flakes with the tape.

And an old garden hose or foam pipe insulation wrapped around the frame and taped in place will protect the finish while taking the motor out or putting it back in the frame.

Looks good so far though!

Quote from: Big Rich on October 10, 2010, 01:22:38 AM
Just curious, did you paint the motor with high temp paint? Until it's properly cured, it may come off in little flakes with the tape.

And an old garden hose or foam pipe insulation wrapped around the frame and taped in place will protect the finish while taking the motor out or putting it back in the frame.

Looks good so far though!

Yes, the motor was painted with Dupli Color 1200 degree Engine Matte Black, was cured in a 90 degree garage for like 4 hours, and has sat for over a year all bagged up waiting for me to get off of my lazy arse and start building this thing, it's held up quiet nicely.

Hey Fry, can you show how you mounted the mesh on the subframe?

Quote from: centuryghost on October 10, 2010, 07:10:23 AM
Hey Fry, can you show how you mounted the mesh on the subframe?

The mesh is used in commercial grade loud speakers, I have it in big 3'x3' sections and just cut out a cardboard template of the area I went to inset it in, lay that cardboard over the mesh, spray paint around it, then use a cut off wheel to cut out the piece. I then Mig weld it in from behind. I was going to put a nice thin bead of seam sealer around the outside, visible edge but now that everything is coated it looks ok, slight gaps and variations aren't all that visible. I also mad a tray out of this stuff to relocate all of the wiring, relays and electronics under the seat.



I screwed this one up (Upper right corner) but you get the idea, once pressed in there I tac/welded it from behind.



Electrics tray

Pretty cool Yankee Ingenuity. Gives a unique look for sure. So how much more time you figure you have left on assembly?

Quote from: JB848 on October 10, 2010, 05:10:27 PM
Pretty cool Yankee Ingenuity. Gives a unique look for sure. So how much more time you figure you have left on assembly?

Thanks....

I spent the day with these so I didn't get much done today, just installed all new bearings and spacers in the Swing Arm and installed it on the bike. Next I need to detail the shock and install that.

Guns, Yummy.




I felt guilty spending the day at the range, least I got something done on the bike today.




Probably about another 2 months before I try and start it, probably 4-5 months before it's fully assembled and 100%...

BS do it quick and do it now...more pictures please?

Got alot done on the bike today, got the Side Covers On, Valve Cover, New Clutch and Springs put in, New Crank Seal installed, Lubed every with the clutch acctuator, installed a new clutch cable, basically installed all the shiny new powder coated pieces, all new gaskets, seals and such.

Not home tonight but I took lots of pics and will post them up tomorrow.

Next on the docket is to install steering head bearings and races, triple trees and get the forks on, hopefully I'll get that done tomorrow.

As promised here are the recent pics...

Cam/Valve Cover Installed, had to do it twice, 1st time I forgot to put the cam chain buffer on the bottom side, Doh!!!



New Clutch and associated hardware installed, crank seal installed and greased, and cover put on for good.



Hope all of this is correct? Made sure the crank pin engaged/locked into the middle piece, hopefully the timing isn't messed up, nothing else was touched in the timing/valve train.



All buttoned up, I wont be buying the Suzuki Round Sticker for the front of the side cover.



I found these little round metal disc's in my garage that I will do something with..







Clutch Actuator all cleaned and greased, with the mystery ball bearing re-inserted...



Going through it's range of motion, testing it out to make sure I had it fitted correctly...





This next picture is causing me great anxiety and I won't know for sure until much further down the road...These 3 bolts for the Stator went in very hard, and the 3rd 1 in got stripped/cross threaded somehow, this is the furthest it will go down, and it was very hard getting it to this point. All 3 have loctite on them, and the other 2 are really tight, possibly cross threaded themselves as well. I'm thinking there might have been sand in the threads from sand blasting the covers, and it F'ed up when I ham fisted them in. There is no movement in the part, and test fitting it reveals? that the raised screw head doesn't hit anything once bolted up to the motor, hopefully I wont run into issues with this? I know it's really hack, but I would have ended up really creating a ton of work trying to get it out of there, I'd have to travel to my Brothers to get metric taps, it would have been a mess, just keeping my fingers crossed at this point, feedback please on this potential causing an issue.



Shifter side all buttoned up, new clutch cable installed. I'll will be using the metal discs to use on this side as well instead of the factory Suzuki emblem.



Cylinder and Head un-tapped, I like the look.









I'm gonna try and get the Triple Clamps and new steering tube bearings installed today, perhaps even the forks though I still need to paint the legs of the forks.

Well, I was able to get most of what I wanted to do today, done. Got the new Steering Bearings and Races installed. Got to adjust the pre-load and attach the top clamp and associated hardware, it looks good, and went together smoothly.

New Bearings, Powder Coated Lower Clamp. Took some Emery cloth and really cleaned up the bearing surfaces getting rid of rust, corrosion and powder coating on the bearing seats. Also sanded the holes were the forks come through, there was a bit of an edge with the PC'ing.



There was a lot of baked on Sand from the Sand Blasting/Powder Coating Process so I cleaned these areas out with a die grinder/wire wheel combo.





No that ain't blood on the towel, LOL....







Bearings packed, everything cleaned and lubed waiting for assembly.



Top Race put in.



Bottom Race installed.



Lower Bearing installed.



Loosely fitted.





Loosely fitted, I like the contrasting of the 2 top clamps.





Time to watch some football, probably will go out to the garage later tonight and get the fork lowers prepped for paint, finish setting the pre-load on the bearings, and final assemble all of the Triple Clamps and associated parts and hardware. It's getting close to being a roller again.

Decided to do a bit more work. Cleaned and assembled the Gauges, Dash Panel/Bezel and mounted it. I may take off the Middle Triple Clamp as it's gloss Black paint is faded and hazed and though looks OK IMHO after cleaning, it would look better with a quick, fresh coat of Flat Black.

Here are the latest pics...

Got a bit more done today. Painted the Fork Lowers, Painted the Shock Cushion Lever, and cleaned the Shock. Got most of the rear suspension done only hold up was a missing Cushion Bolt, had to order a new one. Got the Forks Installed as well. Also touched up the wheels as the got a few scrapes on them, I painted them like 2+ years ago, sitting in my garage un protected gave them a few nicks...

Shock Cushion Lever quickly painted.



Wheels touched up.



Forks Primed, then painted a Satin Black.











Well, that all for now, probably for this week until I get some parts in....

Wow! Fry everything look beautiful. I am surprised you painted the forks after all of the detail you put into your project. By they look very nice besides the point.

Can't wait to see the rolling chassis!

About 2 years ago I rebuilt the Forks and was so far away from painting/finish options, I just assembled them and put them aside. I should have had the lowers Powder Coated as well yet at the time I had no clue and I was not pulling them apart again or waiting 2 weeks for them to get powder coated, so I took a risk with a rattle can and got good results, color and texture wise there not an exact match, but it looks acceptable.

I was so methodical with labeling and bagging all the parts and bolts I'm really pissed and at a loss for where 1 of the 3 Rear Cushion Lever Bolts could be, it's the only thing that held me up today, otherwise the rear would have been final assembled and Trq'd to spec. I should get a discount at Ron Ayers with all the little odds and ends I've been ordering of late.

I need to clean, paint and detail the Discs, Clean Paint and Detail the Calipers and M/C, for the mounting of the wheels, that's this weeks/weekends goal, get the tires on it and make it a roller.

The seat isn't going to sit that high is it? It'll sink with the weight of you + the bike, right?

Quote from: ragecage23 on October 18, 2010, 07:33:14 PM
The seat isn't going to sit that high is it? It'll sink with the weight of you + the bike, right?

It isn't seatd into its mounts in the pics, and I have to shave the bottom side of it a bit to get it right...