ok, so i spent all w/e on this thing (my 500cc soon to be 605cc money pit)......ALL W/E!! Nice weather for it anyway. Things Accomplished:
Stripped and finished prepping the frame for p.c. (still have to weld on the rearset mounts and figure out the rear brake attachments.
Stripped and ground all the tabs and things off the swingarm.
Strpped, sanded, polished, buffed, & clearcoated the rear hub. Oh and drilled it too. looks cool now.
Stripped the rear rim and spokes (17" from a 750 for more meat on the tarmac). Surprisingly the spokes stripped easily and shine really well. Left them in carb cleaning solution for a day then sanded them with 380 and 1000 paper.
cleaned all the rust off the rims and oh boy what a mess!!! well they are ready for p.c.now.
cleaned all the engine and nut and bolts and prepped for paint.
painted the engine!!!! looks really good now. the case covers will be polished like the hub.
Stripped the front caliper but have to get a rebuild kit. and started drilling the rotor but got bored after about 20 holes, LOL.
and then there was the forks......EEEK. Of course there was the usual rust behind the boots but they were a mess. the previous owner had polished the clear off the legs at some point and the exposed Aluminum had oxidized and it took forever to revive it. While tearing them down i drained the mucus out of the legs where there should have been something that resembles oil. not pretty. anyway i finished one but still have to wait for the seals to come in to reassemble. I cut about 2" off the bottom of the springs (progressive part) and added spacers. they consist of 2 washers and a pvc coupling. Simple but effective. See pics. This will take the plushness out of the ride and make the suspension more predictable. I also filled ing the 2mm seepage holes at the base of the cartridge and drilled new 1.2mm holes to slow rebound and will fine tune with different weight oils. I will start with 15 and work my way back. My guess is that it will need 7w after all is said and done.
And now for a couple questions:
1. I cannot for the life of me remove he drive plate from the cush drive!!!! I went as far as putting it in the oven for 1/2 an hour and nothing!!! wont budge. I have a spare 750 hub the just fell out when dissasembled so i can see the if it was me or actuallt the hub. it's the hub. I know now i definitely have to replace the cush rubber but i cannot get to it. any ideas?
2. I am not planning on re-using the boots. Does anyone know if there is a dust seal that fits the legs?
