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!