Also there’s some really good documentation on this site like original shop and parts manuals. The exploded diagrams have helped me immensely on this project.
This is my first 500, but it’s also my first project like this that I’ve ever dug into.
I’ve learned a lot over the past 7 months or so, and this dude is just about ready to test drive.
Back to the matter at hand, though; I dropped off my tank with a local reputable body shop a couple weeks ago. I have a pretty good rapport with the owner, we give him a lot of business at my day job. I asked if they could smooth out the dents and prime it for me, which they did. I went back to check on the progress yesterday, not expecting it to be ready, but it was done. No charge, which was very kind. I wasn’t able to bring it home though, since I was on my Suzuki.
In preparation for the newly refinished tank, I took some time this evening to reassemble everything. Repainted the engine side covers that had been removed, reinstalled the clutch plates after an overnight oil soak, mounted up the chain guard, fixed some electrical connections, adjusted the clutch, moved some wiring around, and basically did a bunch of things. You get the idea.
I wanted to ask about hardware for the gas cap. The original pins are a little pricey, and I don’t think I have an appropriate tool to install it. I vaguely remember reading about tiny bolts that could be used? Like M3s, maybe? I’m probably gonna go that route.
I replaced my handlebar switches with the ones I was advised not to buy, they’re 1000x nicer than the ones that I had. Very small, very utilitarian.
I finally found a store that has the front turn signal stems in stock, ordered some of those and some dust boots for the front forks.
I’m glad to have had an opportunity to tear into this again, it’s therapeutic.
