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I got a nice stainless steel front brake line from Galfer. Their website even let me search for a line compatible with my ‘85 model which I thought was pretty cool.
 

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Discussion Starter · #223 ·
I snapped off a headlight bracket and had to replace it, but it was alot easier than I thought it was going to be. Been working on front brake shoes and caliper and today buttoned up the carbs:
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Discussion Starter · #224 ·
Carbs went onto the new boots with no hassle. Air boxes needed a little more fiddling but went on okay.
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Discussion Starter · #225 ·
Moving slowly but getting some stuff done. Bar end mirrors and grips installed
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Discussion Starter · #226 ·
Master cylinder and new lines in. The front wheel is still dragging at the caliper. Maybe it will smooth out when the fluid is in and the lines are bled? The throttle cables are in too. They are kind of long for the shorter bars but I think they will work.
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Discussion Starter · #227 ·
Hi folks: another wrenching season has begun. I started with a brake bleed (all new m/c, hoses and caliper) and all was well but now I have a leak from the caliper. Took it apart and yep, leaking from under the pad on the "thick" side.

So what to do? Everything is new and shiny! How do you seal it so the fluid doesn't leak?
 

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Discussion Starter · #228 ·
Hi folks: another wrenching season has begun. I started with a brake bleed (all new m/c, hoses and caliper) and all was well but now I have a leak from the caliper. Took it apart and yep, leaking from under the pad on the "thick" side.

So what to do? Everything is new and shiny! How do you seal it so the fluid doesn't leak?
Turns out I had the seal in wrong. I think I have fixed it.
 

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Also, did your caliper piston have any marks/gouges or pitting? Mine has a small amount of pitting but I think it should still be good to use
 

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Discussion Starter · #231 ·
Also, did your caliper piston have any marks/gouges or pitting? Mine has a small amount of pitting but I think it should still be good to use
My piston is brand new. I had the seal around the top of the space for the piston instead of in the groove in the piston hole. Durrrrr.
 

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I don’t suppose you’d be able to post a pic of how your diode & holder is mounted?? I think it’s either on the coil mounting bolt or on the horn mount. I can’t seem to find any quality angles to see it from
 

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Discussion Starter · #233 ·
I don’t suppose you’d be able to post a pic of how your diode & holder is mounted?? I think it’s either on the coil mounting bolt or on the horn mount. I can’t seem to find any quality angles to see it from
I'm afraid I don't know what you mean by diode and holder--do you mean the starter solenoid? Or the voltage regulator/rectifier?
 

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Discussion Starter · #234 ·
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Moving on with the front brake sorted: if you think a little piece of rubber can't cause a 60 minute battle you're incorrect. I tried about 10 different tools and various strategies to get that thingie in the fender loop.

Next I took the bike off the lift to get the stands on. I hung the bike from the shop rafters:
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I installed the sidestand spring with a loop of strong wire and brute force. The center stand needed more leverage, so I used a comealong anchored to the floor with a screwed eye bolt.
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Discussion Starter · #235 ·
I put the new petcock on the green tank and tried it on the bike with the seat.
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Discussion Starter · #236 ·
I tried and tried to get the original airboxes to fit, but to no avail. So I will try the pods. That meant making a battery box to fit around the pods. Here's where I am at now: I used bent and riveted aluminum to make the box. The rectifier attaches at the bottom and the solenoid and flasher relay mount on the side.
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Discussion Starter · #237 ·
The right side exhaust pipe is nice and snug but the left side isn't. Why?? There doesn't seem to be any difference between the two pipes or connectors! Is there a good way to shim it?
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Discussion Starter · #238 · (Edited)
I had the collars backwards.
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Don't do this.
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Collars face out and flanges don't meet the head flush.
 

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I'm afraid I don't know what you mean by diode and holder--do you mean the starter solenoid? Or the voltage regulator/rectifier?
I'm afraid I don't know what you mean by diode and holder--do you mean the starter solenoid? Or the voltage regulator/rectifier?
this little bit they list on the parts fiche as a “diode”, I think it’s part of the safety lockout for the starting system. I’m just unclear on where exactly it mounts
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