Jennifer's Makeover

[Flyboy]

Thanks Ed, understood, probably a knackered thrust washer/bearing/whatever, I have never had the clutch out, so all the bits will most certainly still be there.
Will pull the whole clutch basket off nect weekend and have a peek behind it and see if I can see anything.
Thanks for the informative feedback.

 

[samboss260]

After's

Nice !! What did you use to paint the silver and the black? And how fuel resistant were they? This is the look I am going for.

 

[Flyboy]

Thanks, I wanted to spruce the carbs up, inspired by RenoBuce's work, but the black bodies and polished tops and bowls has been done to death, I wanted something different, swapped it around.
Used a plain garden variety 2k urethane, how fuel resistant it will be, your guess is as good as mine, guess we will find out.
Trick is to keep the fuel inside the carbs, no?

 

[samboss260]

Thanks, I wanted to spruce the carbs up, inspired by RenoBuce's work, but the black bodies and polished tops and bowls has been done to death, I wanted something different, swapped it around.
Used a plain garden variety 2k urethane, how fuel resistant it will be, your guess is as good as mine, guess we will find out.
Trick is to keep the fuel inside the carbs, no?

Spot on !!!

I will be going with a tough coating of Chassis Kote on the lids and bowls from POR-15 range. And Eastwood's Carb Renew II on the bodies.

 

[londonboards]

Thanks Ed, understood, probably a knackered thrust washer/bearing/whatever, I have never had the clutch out, so all the bits will most certainly still be there.
Will pull the whole clutch basket off nect weekend and have a peek behind it and see if I can see anything.
Thanks for the informative feedback.

Yes these clutches are a pain.

https://www.youtube.com/watch?v=_Mh7AzXLOnU

I've pretty much tried everything now with 2 of them. Yes you will get some rattle from the springs but it sure wouldn't make a noise like that on the video. I think you are nearer the truth with that lateral play. If the noise reduces when you pull in the clutch then it may be (not certain at all) that the lateral movement is causing it. If the clutch nut is tight then the only reason for the lateral play is that the width of the clutch hub is less than the width of the clutch spacer on which it sits (with a needle roller in between). I read somewhere that someone had ground down this spacer to match the width of the the hub and had eliminated the noise completely. Other people have said if you grind down that spacer you will destroy it's strength. Don't know who to believe. I might try in on a spare.

Either way when you take the hub off don't lose the little (is this the smallest part on this bike?) cushion rubber part no. 21215-49000. I put new ones of these in but it made no difference.

Greetings

 

[rustybronco]

Disassembled all the lenses from the gaskets and cleaned them. Washed up all the plastic housings, rings and what not's in the sink. Dried everything and reassembled both tach and speedometer using Daniels km/h speedo and tach he sent, choosing the best faces of the lot for the tach. Locktited all the little screws that are known to come loose holding the gauge faces and re-cemented the light diffusers inside the housings which had loosened over time.

I still need to clean the wiring harness and repair the split in the plastic loom covering as best I can, but they are starting to look like they may be quite presentable after all.

As they sit so far...

 

[81suzi]

put some miles on 'er this spring!!!!!!!!!!!!!

 

[Flyboy]

 

[Flyboy]

81suzi, we going into winter here now, but its all good, we ride all year.
A labour of love that is approaching four years, trust me, the day can not come soon enough.

 

[rustybronco]

Got to spend a few hours this afternoon taking apart the wiring harness in order to replace the damaged loom sheath on the best of the two harness. Decided to take apart, clean the best of the hard shell connectors, and everything else while I was at it. Checked all the light bulbs with my trusty Simpson 260. Found a few bad including one used for the gear indicator.

Now all that's left is to repaint the bracket and they'll be done.

Got to make the inside look as nice as the outside.

 

[Flyboy]

Sjoe, that is taking care of the details, can't wait to mount those onto Jennifer, I am itching and becoming very grumpy and impatient.......Grrrrrrrrr.

 

[rustybronco]

Understandable after waiting four years my friend. Soon enough. Just need spring to arrive so I can paint the mounting bracket.

 

[Flyboy]

This weekend was spent doing more menial peasant work, sorry, nothing exciting or picture worthy.
Sepent most of today sanding my stator cover for polishing, that I got from Ed, I swore I still had a full can of paint stripper, but could not find it, so it was hours with the 220 grit sandpaper to remove the clear coat.
Also checked the stator while it was out, reading 1.6 Ohms between all legs and infinity on all legs to ground, so good to go, will bolt it into the cover as soon as I am done polishing it.
Cleaned up engine mounting brackets and started bolting the engine into the frame.
Checked clutch hub nut torque and buttoned up the clutch cover.
fitted the coils.
Fitted the shaft boot between the engine and swing arm.
Bought intake boot O-Rings for the kings ransom of R12 ($1.13) for the four.
And paint to finish the front mud guard and fairing.
Confirmed I will have to remove the top triple and headlight ears again, to remove the chrome trim that covers the bottom triple.
The "S" fairing will not fit with it in place....damn.
Jury is still out on what to do about colour on the fairing.
Guess I could always ride it naked, as it was meant to be.............nah.
Need to order one shim (2.68) then I can button up the valve cover and pretty much call the engine done.

 

[Flyboy]

So today I was planning to go through to the classic bike club get together that happens every first Sunday of the month, but decided to spend as much time in the garage working on Jennifer as I could, was in the garage at 7am and only surfaced about 7pm, had a productive day, got a whole bunch of stuff done, nothing major that I wanted to, but tying up little odds and ends that bring it all together.
Finished polishing the stator cover, mounted the stator in it and put it onto the bike.
Pulled the cams and finished off the valve clearances, so the motor is all buttoned up and done, except for a new oil filter and a new set of plugs.
Went through the brakes and replaced all the copper washers with new.
Removed the chrome trim from the lower triple and put the front end back together.
Fitted the clutch cable.
Fitted the Tach drive.
Fitted the rear brake pedal as well as the gear shift lever.
Finished painting and fitted the engine mounts as well as polished and fitted the seat brackets.
And a bunch of other little odds and ends.
Sat on her and made revving noises.

 

[Guest]

Sat on her and made revving noises.

Always the best bit

 

[Nessism]

Sat on her and made revving noises.

Nice!:!:

 

[cowboyup3371]

About time Stan...Congratulations on that first small step:dancing:

 

[Flyboy]

Ok so it is the long four day Easter weekend and my tribe have buggerd off into the bush to go fishing so I am on sports pass and solo this weekend.
So instead of getting up to mischief, I decided to spend it in the garage playing with another female...Jennifer.
Yesterday I got the front mud guard and the fairing done, the jury was still out on how to lay the colour down on the fairing right up to the minute I was holding the fine line tape in my hand, so I had another beer and let the light guide my hand.

I am pretty happy with the design and the way it came out, and it fits seamlessly into the flow of the OEM decal kit, will let them cure for a week and then wet sand and polish next weekend, may lay down a few more coats of clear on the fairing, will see how it goes.











Mocked up the carbs and airbox.........look alright.

 

[harley10]

Looks great man !! You deserve another BEER!!

 

[Guest]

Looking good.