Complete!

After 107 days and about $1500 worth of paint and parts, we are finally done!

We got the radiators back, day before yesterday...they were holding us up on finishing the project.  We sent them off to Myler's in Utah and originally ask for the straightening AND reinforcement.  They came back straight, but with no reinforcement...That's OK though, they will work just fine the way they are,  beats what they looked like when we got the bike!

Installed the muffler and silencer, which look awesome on the bike.  The longer silencer fits nicely with the two attach points, wasn't sure if it would or not.

All in all, the whole project went really smooth, smoother than we expected...a little more expensive than we expected though!

We still need to fix a couple things, rear wheel spokes being the hot item next on the list.  I would like to get each wheel hub powder coated, but that is not on the radar right now.

Here are the radiators prior to the straightening.

And back from Myler's all nice and straight!

FMF Fatty...Looking good!

FMF Turbine Core 2 (No top mount bolt yet in this pic)

And her she is!  Beautiful looking bike (to us at least, and that all that counts!)

Here is the first kick after the rebuild!

Thanks everyone for looking, I'll keep this page up with new riding pics/videos every once in a while.

After Christmas fun!

Happy Holidays everyone!  Christmas was pretty good this year for the bike.  Got in a lot of parts to help finish it most of the way, we still need a few parts though.  The coolest thing Santa brought with him was an FMF Fatty pipe and a FMF Turbine Core 2 silencer (which I need to figure out how to put on!).

We put the air box and sub-frame on today, along with new sprockets and chain...and yes I know that when you look at the pictures, there is no chain slider on yet, Santa forgot about that one!  We prepped the radiators to be shipped out to Myler's in Utah to fixed and strengthened also.

We will be heading to Boise here soon to pick-up the rest of the parts we need (hopefully!), and try to have this done soon.  We have the chain slider and two chain roller guides on order...On to the pictures!

Ahh...FMF...now to figure out how to bolt up the silencer mount below his hand!!

Changing the front sprocket...had to put the chain on to keep it from spinning

Rear sprocket...Changed from 51 tooth to a 52 tooth

Putting some semi clear rubber tape on where the air box rubs the sub-frame

The tape turned out pretty good, can't hardly tell it's there

Torquing down the sub-frame...be sure to put the air box in first!...lesson learned.

And the finished product for the day

Should be mostly completed next time I update, the longest thing we will have to wait on are the radiators, but I hear that they have a quick turn-around.  Can't wait to see it finished!!

Front end installed

We finished installing the front end, minus the handle bars.  Followed a few suggestions on what to do with the castellated nut, we tightened it until the turning the forks were binding just a little, then backed the nut off until there was very little binding left.

That will be one of the first nuts I check once he starts riding again!  Hate to have it come loose, although it shouldn't with the top triple clamp sitting on it.

The paint job turned out to be a little more orange than we thought, compared to the new fork protectors.  It ok though, it still looks really good.  I couldn't be happier with how it has turned out so far.

We are pretty much going to be on hold until after Christmas.  We are running out of parts and we will see if Santa brings anything...Hopefully he will, I want to see this bike done and running again!  Until next time, have a Merry Christmas and a happy new year!

Installing the new fork gaurds

A little further

The bearings for the linkage, where the rear shock lower bolt goes into, finally came in.  We changed out all three (actually 4) bearings, and got the ball rolling again.  Once the bearings were done, we installed the linkage, rear shock, rear tire and rear brake system. 

We started  to do the front suspension, but came to a stopping point, scratching our heads.  How do we torque the castellated nut that sits on the upper steering stem bearing?  Anyone done this or know how to do it without the "special" Honda tool?  Let us know!!!  Anyway on to some pictures!

A little heat on a stuck bearing works (almost) every time!

Linkage bearings done, shock installed and being torqued.

Rear brake system almost done.

And...rear tire installed!

And last but not least...how to torque the castellated nut without "special" tool?

Once I find out how to torque the steering stem nut, we can proceed with putting the steering system together.  But until then let us know how we are doing!  Give us a little feedback on what we can do to make the build even better!

Rebuild started with engine and swing arm!

We finally got the swing arm bearings in, and installed.  But when we were about to install the swing arm linkage, we found something that I totally forgot about...the bearings in those.  What is it with us and bearings?  Anyway, those are now on order too.  So we have the engine, swing arm and the electrical system installed.  It is starting to look like a motorcycle again!

 Bearing install with our special homemade tool!

Grease the bearing really good!

Bearings installed and swing arm ready to install

A little sanding on the holes so the bolts will fit

A lot more grease this time added to the swing arm pivot bolt

Add a little torque to the bolt

Add some electrical components...and this is what we ended the day with.

Great looking bike so far!

Here is the linkage that I forgot to bearings for.  Just trying to find out how to remove the bearings where there are two in the same opening.

Once the bearings for the linkage come in, we will take it and get the bearing pressed out and installed.  We are still waiting on the steering stem to come back from the Yamaha place so we can install it on the bike.  Hopefully it will be ready tomorrow...fingers crossed!

Steering stem bearing...

Took the stem to our local Yamaha dealership (only choice I have in this town), and they froze the stem overnight and then...they bent the bearing while installing it.  I asked them how they have done bearings in the past, and they said uuuuhhhh.....  I had them order the correct tool for the job (at no cost to me!) and they also ordered a new bearing.  Supposedly will be done this coming Wednesday.   We'll see...

Did some bearing work today...

We decided to tackle the lower bearing on the steering stem today.  The first thing we did was take it to the local Yamaha dealership, of course no technician was working that day!  So one of the guys there tried using a hammer and punch (we also tried that), but all he managed to do was make the roller cage come off.  So back home, I pulled out the Dremel with a reinforced cutting wheel on it.  I cut most of the way through the bearing, tapped it with a hammer and punch, and it broke loose and came off really easy!  I will take it back and have them press the bearing on though, it will just be easier.

Like I said before, we received the bearings for the bike, but instead of the swing arm bearings we received rear wheel bearings.  So in the meantime, we decided to go ahead and install the bearings into the linkage.

I used a set-up I found on the internet to press the bearings in.  It is basically a continuous thread bold with a couple washers, one of which just fit into the hole allowing us to get the bearing flush.   Worked really well, I was surprised!

Be sure to grease it real good!!

Now to apply a little pressure with the homemade press.

  

 Install the dust seals...

And the final product!  Ready to be installed and hopefully never cut out again!

Now its just a waiting game for the swing arm bearings, and then we will be able to install the engine and swing arm.  Make it start looking somewhat like a motorcycle again!

Top end done!

UPS guy was kind enough to deliver some engine parts for us a couple days ago!  Now that we have all of this we can start the top end rebuild.

Upon opening the package, I found out that I forgot a rubber grommet that goes on the left HPP valve.  Order that and now that we got it in, we completed the rebuild of the top end.  Justin had fun doing it, seeing what the internals of the engine look like and learning how to use a torque wrench in the process.

Everything felt real tight on the bottom end, therefore I didn't worry about pulling the two halves apart.  That would have been an adventure all by itself, glad we didn't have to do it!!

Top end removed, new piston and seal installed

Justin lubing the HPP valves

And the finished product...and just by feel, it has way more compression than before.

Bearings for the bike were shipped out today, so once we get those in we will start doing a little assembly work.  Justin and I are ready to see it start coming together!  We should have the motor, swing arm, and front end installed on the next post...I hope!

Got the frame back!

Took the frame to Boise last week, and picked it up this afternoon...WOW!...very impressed with the work that was done on it.  Epsco did an excellent job on it, and they said that it was one of the best they have done (they probably tell that to everybody!).  We tried to get it as close to Honda red as we could, but non the less it still came out awesome.  So here it is in all it's red/orange glory!

So now all we need are the bearings, and we will be able to start putting it back together.  I think the hardest part will be trying not to scratch it when putting it back together.

Well let us know what you think, and any suggestions you may have on the rebuild, and keeping it scratch free!

Until next time!

Frame repairs

Well not much to post right now, I took the frame and sub-frame to Vic's and him replace a couple stripped out nuts.  And as usual here are a couple pics to show the progress!

First is the main frame nut, this nut is for the left side gas tank mount

Next is the sub-frame, this nut holds the silencer onto the frame

Monday we are taking the frame to the powder coating place.  Justin wants the frame to be red, so I want him to be the one to pick out the right color...I afraid that if I pick the color out, it won't be what he wants, and I want this bike to be his just the way he wants it.  I'm proud of him for taking on this project, it's really been fun!

A little motor prep work

Justin and I went out this afternoon and decided to find out what the top end looked like.  Seeing all the pistons and heads on the internet that were just completely mangled, and cylinders all scraped, I was scared to see what it looked like.

Well I was pleasantly surprised too see this:

and this...

All in all I was impressed with the condition of both, the piston has some carbon buildup on it, but it and the walls are in great shape.

Next we took out the reed valve...I'm assuming it is OEM, but the reeds look real good also.  From what I have read, the reeds should be what they look like in the pictures below.  I anyone sees something wrong with please let me know, I have never messed with reeds before.

The next thing we did was clean the HPP valves, quite dirty, but cleaned up pretty good.  Everything seems to move smoothly and there are no apparent signs of damage or anything.  Forgot to take a "dirty" picture of the right side, but got one of the left.  So here they are right (clean), left (dirty).  Cleaned them up with a toothbrush and some brake cleaner.

I guess the only thing that concerns me about the motor is in the pic below...there are some cracks in the area of the rear motor mount.  I'm not sure if they are just paint cracks or actual cracks.  What do you think?

Bearing play on the crank felt good, just a very little bit of side-to-side play, but if I tried to twist it there was nothing.  Anyone knows the correct way to check please let me know!