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Hi Everyone I did not get to work on the bike much since last week, the head cold turned into some sort of upper respiratory Infection lots of Coughing up of stuff , fever and Headache. Spent Friday , weekend and today feeling like crap. Did manage a couple hours in the garage yesterday and part of the afternoon today, I managed to get the Rad Hoses installed and Rad mounted so I am ready at anytime for Anti-freeze/Coolant, Re-installed the Coil Bracket and coils and installed the new Plug wires and Iridium Plugs. Installed all the remaining misc Hoses Vacuum Pulse Hose Breather Hose(also installed the Baja Air filter) all new Fuel lines from the Tank outlet to filter -new filter- from Filter to Pump then new line from the Pump to the Carb all visible hoses are sleeved with SS Braid Put all new Spring and Screw clamps. I found these 2 kits on Amazon both kits were under $20 ea Nice to have in the shop Installed the Fuel tank and rear subframe started to finalize the Forward controls on the Right side then ran into a snag the new master cylinder Banjo Bolt threads are different M9x1 versus Yamaha M9x1.25 Hopefully i can source one locally and then ran out of steam. I have also included a Picture of the Russell Brake lines I am using these are Factory made and DOT certified for US/Canada . as always here are some pictures to update you all on the progress. Have a good Night Herman

Hi Everyone I wrote an update on Sunday Nite but for some reason it did not post, I spent the first hour or so going over the Bolts installed the previous day to confirm I did not miss any and checked for correct Torque, refilled the Final Drive with new 80w90 gear oil. I spent some time test fitting the Vmax Silicon Hose set I purchased off amazon and made a list of Hoses and clamps I need in order to replace all the hoses on the Bike. Only one hose was too short for the Top Rad to the Fan Sensor tee, but I was able to source a piece of hose at a local Industrial hose supplier, the other issue I ran into was the Hose Diameter was about 3mm larger and the Spring Clamps would not go On the Hose so I found a kit on amazon with the larger Clamps I need. Also finished putting the Head bearing races in the Frame and Mounted the Triple Tree and then went to work on assembling the Front forks. Finished up Sunday Evening by Polishing the SS Exhaust Pipe I built and cleaned up and polished the Front Cylinder Pipes. Monday Morning I was off to the Hose Supplier to pick what I needed, then back in the garage. First order of Business was to install the Exhaust on the Bike, then I went to work on making the Block off plates for the Front forks and gave them a coat of Paint to match the new Black Lowers. Replaced the Clutch Slave Hose and re-installed the Steel Clutch Line on the frame and installed the new Speed bleeder. Filled the forks with new Synthetic Fork oil by Amsoil (10wt) as suggested by Progressive, installed the Springs then closed them up. Changed out the front Axle Seals and checked the bearings they were clean and turned smooth with no play so I opted to leave them and repacked them with bearing grease then installed the Front wheel. The bike is now back on both Wheels with new tires. Went to work on dismantling the rear subframe to get it prepared for a fresh coat of paint, and the day was done. Toke the Nite off from the Garage tonight as I feel like I am coming down with a cold so I will get some rest over the next couple nights and go back at the bike on the weekend. I am hoping to get the remainder of the Mechanical work complete over the weekend with the front and rear subframes re-attached, rebuild the 3 brake calipers, and finalize all the different plumbing, hopefully test fire the Engine again to fill the engine with Antifreeze. That is it for now have a great week all Herman

Hi Dano When I first purchased the bike roughly 5 years ago I signed up on this great site and researched thru all the info on this site and basically toke all the advice and recommendations then decided what I envisioned for my project, I am the type of guy that likes to work on things and make them my own so for me the upgrades serves multiple purposes it revives an old bike , I am using modern materials that improves reliability and safety, it also tests and improve my abilities and workmanship. because it is an older bike it is simple in its functionality and easily modified even with all its advanced electronics of that day, as an electronics Technician the wiring and electronics do not bother me. I have always worked on my own mechanics of my cars Snowmobiles and boats and Motorcycles and enjoy the work. Did I need to do all the upgrades, No , but when I look at the age of the bike and during planning I will always plan to replace wearable parts , brakes, bearings, bushings, seals, hoses, brake lines etc. because you just do not know if the previous owner actually maintained things. the other reason is I have the Tools, ability and garage space to perform this restore/upgrade so why not, much more fun then sitting on the couch watching the tube. take care Herman

Hi Everyone Here is an update on the Bronze Bushing replacements and Installation in the Lower control arm. The Challenge is finding the Metric Sizes we need for these Swingarms the worst bushings were the 2 that are in the small swingarm link that connects at the Shock lower mount and and the Larger swingarm link. The remainder of my bushings were fine. the 2 on the Larger swingarm link to the swingarm rear mounting points had some wear but was not critical. I have added grease nipples to all 5 points and they are now well packed with grease and the 2 bushings are now Bronze bushings. To accomplish this I purchased from Princess auto a pack of 4 Bronze bushings OD7/8x5/8ID, $14.00, placed this on a 3/8 bolt with washers and put it in my drill press, with the drill press spinning this assembly I used a large flat file to gently mill down the bushing to the required 22MM OD, only need to remove roughly .225mm off the 7/8 OD, once that was done I was able to press in the bushing into the swingarm using my bench vise. Next Step clamp the swingarm into your drill press vise, square it up to the Drill bit then drill the bushing with an 18mm drill bit (amazon purchase $17) go slow using lots of oil. Last thing is to drill and tap for a grease nipple this can be done before or after you drill the bushing to the 18mm. Now an update to the Build my buddy came over to help get the engine mounted in the Frame and I must say it is much easier to install the frame over the engine then muscling the engine into the frame I built a wooden Engine holder out of 2x6 so we could get the engine off my Engine stand and sitting on the Bike lift we then picked up the bare frame and easy peasy engine was bolted in with the new delrin mounts within an hour. We then started reassembling the rear swingarm components and Final drive and Rear wheel with the new Tire. I then started to work at replacing the head bearings and seals, it blows me away how so many MC owners neglect this critical component the Bearings were seized the bearing races were beat to death and not a bit of grease left on the bearings. The bearing Race removal was a bit of a chore as there is now discernable lip on the back side of the race to tap out the old race, so next best thing was to weld the old bearing to the race then pop it out worked like a charm. Front end will be put back together tomorrow as we are heading to family for the day Happy Easter all Herman

Hi Everyone Ignition Module Preventative maintenance was a success tested the module on the second bike and all 4 cylinders are firing as they should I am going to get some more Diodes and do the same to the other module of the Other Bike I will be selling Just for peace of mind. I used 1N4001 rectifiers these are good to 50V and 1A. a solder sucker and Solder Wick is a must for working on Double Sided Boards. Herman