First Kick

So here is some much awaited video.
Here is the first kick after a long rebuild. I have been working on this since August of last year. I took it around the block and man does it scream.

I still have some work left to do (cable adjustments, floor rails, taillight, and minor electric work)

Sneak Peek

So here it almost done. It doesnt have the cowl covers on or grips or a proper taillight or the floorboards on...but this is how it is looking. When it is all done I will take some proper portraits not in the garage.

Back together

So here is the carburetor all back together. With a new choke cable, which after taking these images I tried to install and it is in my sophomoric opinion to tight so I put the old one back on. That is an easy install that can be done without removing the carburetor in its entirety if I need to redo it.

In all Glory

This is where the gas line comes in. I would say the filter is a little dirty. (i also say this because I had to fish out paint chips and calcium deposits from the inside.)
Here is the bowl off with the float assembly in view with one of the jets at its side.
Float assembly removed and all jets out, get to cleaning out all the green gunk.
So I think this is the smallest piece I have had to get down to in this whole project.


So here the carb is broken down into all of its parts. Including the choke cable assembly the float, bowl, o rings, filters, and all jets and bolts. Now to put it back together.

Fuel tap and carb out.

Here it is in all of its glory out of the bike. I had to fix the fuel tap and peck cock while I had the tank out and things all undone. That was just taking it apart and making some cleaning happen. Lucky the fuel tap assembly is ok that would have been another 25 bucks. It is a little hard to get to while riding however to change from on to reserve since it is at the bottom of the gas tank under the seat.
I ended up making my own fuel tap wrench saving 16 bucks. So here are images of that below.




Now that I have the carb out I need to research a bit on which screw does what in terms of tuning. These are the only two adjustments on the outside of the carb that I can find.

The carburetor adventure

So here is an image of where the carb sits in a small frame. Everything is designed to the T and in there tight. So tight that to remove the carburetor you have to remove the seat and the gas tank and be sitting on the bike to have it go up far enough into the frame for you to remove or tighten the hose clamps. So I am taking it out and apart to clean it all out. In all of my excitement I cleaned out what I could see and thought that i didnt want to mess with it right now I just needed to see it run. I should have done this while I had it out the first time. I am learning about expected deadlines of the self imposed nature.

Cables need to be banished

I am having more trouble with brake cables than I would have figured. First there is this little bear of a piece. While trying to install the cable through it. The cotter pin decides to throw in the towel and give up the ghost. It being 9pm on sunday. I make a cotter pin out of a bobby pin, which works fantastic with some filling and bending.
Then installing this was such a beast since I realized after taking this picture that I had to put the pin in place while it was on the bike. So I made TWO cotter pins out of bobby pins since I had to cut the first one off.

Motor Matters

So here is the finished motor on the bench and installed. I am super excited to kick it over. Its heavier than I remember. It is funny I have been moving it around in parts for so long. I used to pick the frame up by the seat area with one hand but now that everything is coming back together, I had just forgotten how heavy it was.

Tires and details.

So here are the white wall tires that are now on PK. I spent the time to detail the nuts and lock washers for mounting the tires. They are all white, I know it will not last forever but it looks good now.
I attached the front Horn Casting and that was a choir since I in my unknowing state didnt put it on before the front fork so I couldnt get a tool under it or my hand for that matter to attach it. I had to put a thin screwdriver through the front grill part and leave the nut visible rather than the screw head, but so be it.

The underside

So here is the foot stand in all of its restored glory. I know road grime and stuff is going to make it look oh so nasty in not so long but as of now I think it looks great. This also was a time when I wished I had taken better notes when I took everything apart. You know at the time I thought my notes were extensive enough and I didnt think I would have to take a 6 week break in the project. But I keep finding parts that i have to look at and think hmmm where did that come from and where does it go. Like on the foot stand there is a small L/J shaped piece that goes on a mounting bolt but which one?



Here is the final foot brake. I am loving the white and black details.

Foot brake

So here is the foot activated brake out of its place. I am having a bit of confusion since I cannot for the life of me find anywhere wires can come from to link to this.
I can see leads on the brake and in the diagram for the bike but those wires do not exist in the wiring harness I have. So...I dont know if a brake light even works on this model but there are wires to the brake light and I know it had one originally. So... I dont know.

Wires and Tigers and Bears

So I have fallen in love with the new heat shrink rubber sleeves I got. I dont know how I existed without them. Next time I break a limb or finger I know what I am going to use.
Above is a picture before and after the conditions of the undercarriage wiring. So much decay on the wires and so much old messy electrical tape.



Before and After of the brake cable housing. I thought I didnt have a new brake cable so I had to use the old one. I ended up having to cut the old housing to get a blockage out and then used the heat shrink sleeves to mend it. Of course after all of this and installing it. I find the new brake cable I thought I didnt have. So now I have a spare and next time I do any overhauling I will replace it.

New cotter pins

Here is the back axel cotter pin. When I got PK the cotter pin was actually a nail cut in half. So I think this will work just fine.

clutch and nut

So one of the issues i ran into was finding a nut to fit the clutch side of the crank. So i found the right size nut but had to cut it in half so here in the final nut cleaned up.



Here is the clutch all installed and good to go. This was a beast due to my cheapness. I made a clutch compression tool out of a bolt, nut and washers. It kept expanding the clutch crooked by just a little and so when it came back together the plates would be off just enough to be super tight to get in. Finally after a while it finally clicked in and was set flush.