It turned 20 years old this year so I'm starting a "Refresh" project on my 92. 

Paint and aging components need work.  A few basic mods just for fun.

I need some advice.  I'm going to be painting the frame.  Does it matter if I remove the the Serial Number / VIN tag?  Is there a way to remove it and reapply?  Should I just mask it and leave it alone?

 
I'll get some pics and a description up soon.

Mask the VIN tag. I think the one on Phenix was removed and re-applied, but I'd be safe and mask it unless doing powder coating as heat might damage it.

Mask the VIN stamped into the steering column. You can get some paint and clear on it but still needs to be visible if you ever intend to sell it to someone that needs an inspection or if it gets stolen and they need the VIN number to know it is your bike.

Thanks Adidas.  I'll keep the tag.

Here's where I'm starting . . .

It's a bone stock '92.  This was my first bike but I want to keep it around because it's easy to ride and lend to friends who are learning.   It turns 20 this year so I wanted to give it a face lift.  Nothing fancy just a refresh and a couple basic mods.


My friend Muggs has the tools and a garage where I can work   He needed some company while he works on his project.  He found an old 1979 Yamaha XS650 that he's turning into a bobber . . . cool project. http://www.dotheton.com/forum/index.php?topic=18034.msg184825#msg184825

Already looks good to me!  What's to fix??

Thanks

From a few feet away it looks terrific.  It was stored in a garage for about 10 years so it's barely used but if you look closely at this photos you'll see there is surface rust everywhere.   

This is kinda what I had in mind.  Sorry about the quality of the image but my editing skills currently consist of cutting, pasting and coloring using paintbrush. 

 

Highlights:
• Flat black engine covers, Stainless engine case hardware, Filed cooling fin tips, Chrome oil filler cover,
• Satin Black frame, wheels, brake rotor centers, calipers, fork tubes, Front fender, light bucket, grab bars
• Chrome handlebars. Reduced fender, updated turn signals, updated mirrors.

Of course, I'm trying to do all of this for very little $$.

Another question. 

There are a lot of plastic, vinyl and rubber parts that need some love.  (i.e. gromets, spacers, chain gaurd, etc.)  They are still flexibile but some are hard or discolored from UV.  Anyone have a good success reconditioning these parts?

I use Mother's Back to Black for plastic.  Inexpensive, easy to get, and it does a great job of bringing faded/bleached black plastic to life.  You will have to apply it several times over a few days to get the best results.

If the OEM bodywork and paint is not all scratched or faded, it's worth more unmolested.

Thanks Adfalchus.  good tip.  How about for hardend rubber.  Any luck?

Good point SAFE-T.  Actually the body plastics are perfect.  I'm going to focus on everything else right now.   

Ouch! I broke one of the header bolts.  That will cost me!   

I'll check the forum for others who had to deal with this calamity. 

Quote from: datel on March 19, 2012, 03:34:36 PM
How about for hardend rubber.

If you're talking about the rubber grommets like where the side panels push into or the rubber spacer connecting the exhaust to the frame then I just replace them.  The same stuff will help blacken it, but it won't become soft and pliable again.

I'm a little high right now! . . .   but it's just from the fumes.

I spent some time sanding and priming the frame and swingarm. 


It may be my redneck roots but I like the look of the primer.  With the glossy black bits and chrome it would look kinda cool.

I masked the VIN tag.  We'll see how that turns out.


View from the garage.  I moved to the garage because it was overcast.  It's beautiful now!  Wierd for March, but I'll take it.

update??

Wow! you guys are real motivators.  I rest for one day and . . .

I spent some time getting suspension parts and stands cleaned up and painted.



I don't know if anyone has experience with this epoxy product from VHT.  Seemed like a good match for the areas that are getting dinged up down low.  It went on easy and cured to a pretty hard glossy finish.   I'd really like to know about long term durability, though.   
 

You probably noticed the shock isn't stock.  I had a SV650 donor that I thought I would try.  I'm using the mod instructions Pablo provided a century ago at http://pantablo500.tripod.com/id39.html.  I still have the old one if it doesn't work out

I haven't decided if I want to spring (no pun intended) for progressives in the front but that will probably happen too.

The bars are bikemaster Daytonas.  I'll try those with some Progrips.

Quote from: datel on March 26, 2012, 04:35:41 PMYou probably noticed the shock isn't stock.  I had a SV650 donor that I thought I would try. 

R6 shock seems to be the latest favorite

A lot more disassembly and parts cleaning but not much to show.  Is there a secret incantation I'm supposed to use to get the key mechanism out of the grab bar? 

I stripped one of the screws that holds the regulator on the battery box.  I'll have to work that out tomorrow.  Battery leaked acid and corroded some fasteners and parts.  Made a mess but it cleaned up OK.   I'll need to make a few repairs and may need to replace some wiring.    I'd rather not have to deal with liquid batteries in the future.  Can anyone recommend a sealed gel battery that fits the GS box?

Next thing is to get the forks disassembled.  I can't put off the decision about new springs much longer.  I hate the way this bike dives when I hit the brakes. 

Well, it's been awhile.  Maybe this pic will help explain why. 

My basement currently holds the contents of a two bedroom apartment (Oldest graduated U Pitt) and college dorm room (Youngest at West Chester U - PA/USA) .  Two more occupants in the house and loads of stuff continues to squeeze the little scooter project to a wee corner.   Look hard and you may see it emerge in the back.

Slowly it is coming back together as I find a few minutes here and there.  . 

I've found that I'm not the most organized guy but it is starting to look like something. 

I really like the change from the original grey frame to satin black.  I put the grab bar on the back just to make it easier to move around and am liking the red/black combo. 

By the way, putting the grommets in requires some ancient Asian talent that doesn't come naturally to guys from the northeast US.  But, some specials words and bloody knuckles finally got it done.

I keep this bike because because it is handy and because it is great to lend and share.  I don't want to modify a great deal but I did want to do a little work on the suspension.  I'm 220lbs so the backend occasionally bottoms.  I bought a second hand shock from a SV650 circa 2000(?).

Muggs comes through again!  It's great having a friend with the tools and know how to get things done. 
It looked like the SV shock could bolt in the way it is but I modified it slightly to better fit the pivot mechanism.  I drilled a new hole in the clevis and removed the unneeded material.  I didn't have a metric bit but a 27/64 inch worked fine.   A hack saw and file did the rest. 


It looks sweet when its installed. 


I don't have the wheels on yet so I can't check how much it raises the tail but I suspect it will be about 1.5 inches.   I'll expect to be modifying the side stand once I get everything back together.