I spent as much time as possible yesterday working on the bike.
First thing I did was clean the chain and front sprocket. The sprockets look fine and I think the chain will last me a little while longer.
I wheeled the bike out into the driveway to do more cleaning. As I was down on my knees cleaning the underside my heart sank when I found this crack on the shifter cover:
After doing some research I don't think this is the fatal issue that I originally thought. Looking at pictures of the gasket and the backside of the cover I don't think there is any oil behind the crack. There also doesn't appear to be any oil leaking from there. The grunge on the bottom of the motor is pretty even and not any heavier on that side. I think it will be okay...
After that little discovery I decided I didn't feel like cleaning anymore so I put in my new tach seal. The old one pulled out just fine with a wood screw and the new one pressed in with a 9mm socket. Before all that I had to cut a groove in the cable screw so I could use a flathead bit in my impact driver. The screw was just too mangled for a phillips bit.
Next up I decided to go big and finally try installing my tapered steering bearings. If you're going to do this job I suggest looking at Hondaman's book and also this thread. both were very helpful.
http://forums.sohc4.net/index.php?topic=1516.125 I did the top race first. After greasing it and getting it started with light hammer taps I got it seated using a hammer and block of wood.
Next I did the bottom race. Again it was greased and started with light hammer taps. Then I put the old race underneath it and used that to seat it. And then popped the old race out from the top. You need something like the old race or a bearing driver because the bottom race sits well recessed into the steering head.
Finally I had to put the bottom bearing onto the steering stem. I had put the stem in the freezer in the morning so it was good and cold (and hopefully shrunk). As per the thread above I used the thinner washer from the all balls kit, then the seal, and finally the bearing. I used the unused thick washer and a screwdriver to hammer down the bearing till it was seated. It was a bit of a harsh method but there wasn't any damage to the bearing so I should be okay. If I do it again I would use a piece of pipe to even out the pounding pressure on the bearing.
After greasing the bottom bearing I went to drop the top bearing on so I could take the whole assembly outside and put it on the bike. I just about had a heart attack when the top bearing wouldn't go on the stem! After freaking out for a bit I went on the computer to make sure I had bought the correct kit. I took it all outside anyways and for whatever reason, after the stem had heated back up, the top bearing dropped right on like it should. (figure that one out!) With everything greased up (and leaving out the top seal as per the thread so that the tree spacing was correct), I tightened the bearings according to Hondaman's book.
With my available time running short I wanted to have a bit of fun. While working on a project like this it's important to remind yourself that this was, at one time, an actual motorcycle. And, God willing, it will hopefully soon be a motorcycle again. Looks good don't it?
There was still a little bit of time left so I put the front forks and fork ears on. I wire brushed the rust off the top of the tubes. I still have to finish polishing the bottoms, and I just put my set of fork seals on the K2 today so the rest of the front suspension will have to wait.
I must say that even though I still have work to do on the motor (polishing), it felt really good to finally be putting parts back ON the frame. Slowly but surely it coming together!!!
