5) Bike Stripped and Waiting for New Life

Disassembly and Labeling Everything

I finally finished disassembly;

 

I took off everything I didn't want or felt I didn't need. Every time I took something off I would see if the bike would start. If it didn't I would re-install or reconnect. So all of the plastic had to go (the fairing and bags), there was a lot of plastic, as well as a very large gas tank. 

I spent a couple days just tracing and labeling all the wiring and vacuum hoses. Tons of plugs/connectors that all seem to have purpose. Again I would disconnect them one at a time and see if the bike would start.

Now the bike is covered with labels detailing each connectors purpose or what all the vacuum hoses were for. This is so after I strip everything off the bike, to clean it up, I hopefully will be able to reconnect them and the bike will run.

The gas tank removal was a nightmare. I followed the shop manual direction which required removing the rear tire, but the darn thing would not come out. First I had to remove the starter which gave me another half inch, but not enough. Then I needed to drop the swing arm so I removed the shocks, which only got me another quarter inch. The swing arm was now sitting on the exhaust system so I had to remove it.  If you have ever removed old, rusty, and seized studs and bolts you know they normally break. And yes I broke a few. But once the tank was out the amount of free space is amazing. I am thinking of building a box in this area for all the electronics.

The new replacement gas tank I bought off Ebay should be here next week. When I finally get it I will see how it sets on the bike and determine how the new gas tank will work (and that is being hopeful). At this point I will be able to start designing the new air box for the top of the carburetors. I will need to get creative because there will not be a lot of room.

The carbs extend above the frame and I am hoping below the two new gas tanks.

I have been looking at various aftermarket air filter systems but there will need to be a low profile adapter manufactured for the top of the carbs. So now I have a lot of planning, thinking and hoping to start bring this bike back to life.