2017 December 23: Cables and side covers (2.00 hours ) Updated: 2017 December 23
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Lubricated all cables with PJ1 Cable Lube . Good stuff.
Assembled the two-way splitter, lubing with grease and applying anti-sieze to the threads. I'm using new replacement cable adjusters that I purchased from Flanders, part number 620-23400.
Fit the upper and lower enricher cables.
Fit the upper and lower throttle cables. The ball keeps popping out of the throttle. I'm not sure what is up with that. I'll have to investigate further.
Used fiberglass resin to do another top coat on the side covers, futher securing the bottom hooks to the side covers.
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Additional entries for this project
2012 October 10: History and plans 2012 October 11: Let the fun begin... (1.25 hours ) 2012 October 12: A possible vision... (0.00 hours ) 2012 October 12: More disassembly (1.25 hours ) 2012 October 13: Organizing (0.50 hours ) 2012 October 14: Degreasing (2.50 hours ) 2012 October 15: More degreasing (1.75 hours ) 2012 October 16: Remove tires (0.35 hours ) 2012 October 17: A revised vision... 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2013 February 05: Pick up gas tank from Bronson's house (1.00 hours ) 2013 February 10: Purchased single gauge dash and speedometer (0.00 hours ) 2013 February 11: Remove broken petcock from tank (0.75 hours ) 2013 February 12: Check gas tank for leaks (0.50 hours ) 2013 February 14: Single gauge dash and speedometer arrived (0.00 hours ) 2013 February 15: Drop off tank at chrome shop (1.50 hours ) 2013 February 15: Speedometer sent out for repair (0.00 hours ) 2013 February 16: Cylinder head and connecting rods ready (0.00 hours ) 2013 February 19: Speedometer shop called (0.00 hours ) 2013 February 21: Call the chrome shop (0.00 hours ) 2013 February 21: Picked up cylinder heads and connecting rods (1.50 hours ) 2013 March 30: Rebuilt the starter (2.50 hours ) 2013 April 05: Forks (1.35 hours ) 2013 April 07: Wheel assembly (1.70 hours ) 2013 April 09: JB Weld (0.50 hours ) 2013 April 11: Powder coat clean up (1.35 hours ) 2013 April 13: Start on fork assembly, rebuild distributor 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(10 minutes ) 2014 April 12: Transmission complete (60 minutes ) 2014 September 22: Drop off more parts for polish (1.50 hours ) 2014 September 24: Pick up parts that have been polished (1.50 hours ) 2014 October 01: Drop off tank at another chrome shop (2.00 hours ) 2014 October 04: True front wheel (1.60 hours ) 2015 February 20: Rebuild handlebar switch (2.25 hours ) 2015 June 07: True front wheel (2.50 hours ) 2015 August 08: Replace spline assembly in rear hub (1.00 hours ) 2015 November 01: Assemble rear wheel (1.35 hours ) 2015 November 13: Clean rear drive, true rear wheel (4.50 hours ) 2015 November 23: Pick up tank from chrome shop (2.00 hours ) 2015 November 29: Assemble and prepare parts for zinc plating (4.00 hours ) 2015 December 01: Drop off parts to be zinc plated (2.50 hours ) 2015 December 06: Rear drive thread repair (0.85 hours ) 2015 December 11: Pick up parts from zinc plater (2.50 hours ) 2015 December 12: Work on generator (2.00 hours ) 2015 December 13: Work on generator (3.00 hours ) 2015 December 17: Flatten engine case and sump (2.15 hours ) 2015 December 17: Work on generator (3.70 hours ) 2015 December 18: Front main bearing (1.50 hours ) 2015 December 18: Work on generator (0.85 hours ) 2015 December 19: Engine assembly (2.00 hours ) 2015 December 20: Engine assembly (1.50 hours ) 2016 January 31: Triple tree, oil pressure relief valve, etc (4.50 hours ) 2016 February 07: Connecting rod shells, oil pump, swing arm (3.00 hours ) 2016 February 20: Install universal joint, misc (1.25 hours ) 2016 February 21: Clean carburetor parts (2.00 hours ) 2016 February 28: Clean throttle and polish small bits (1.00 hours ) 2016 March 06: Throttle and rear brake (1.50 hours ) 2016 March 27: Front brake (1.00 hours ) 2016 March 28: Engine assembly (4.25 hours ) 2016 April 24: Engine assembly (3.00 hours ) 2016 April 30: Generator studs, transmission alignment, clutch hub (1.50 hours ) 2017 November 15: Engine assembly (3.30 hours ) 2017 November 22: Initial assembly (4.50 hours ) 2017 December 01: Assembly and testing for proper fitment of components (8.25 hours ) 2017 December 10: Assembly (3.50 hours ) 2017 December 15: Assembly (5.00 hours ) 2017 December 16: Assembly (5.00 hours ) 2017 December 18: Side covers and breather (1.50 hours ) 2017 December 20: Transmission shift linkage (0.25 hours ) 2017 December 22: Side covers (1.50 hours ) 2017 December 23: Cables and side covers (2.00 hours ) 2018 June 23: Test fit all painted parts (4.50 hours ) 2018 June 30: Remove left cylinder head (0.50 hours ) 2018 July 01: Drop off painted parts and cylinder head to be repaired (2.00 hours ) 2018 July 20: Pick up repaired cylinder head (1.00 hours ) 2018 November 19: Pick up painted parts (2.00 hours ) 2018 November 23: Install painted parts (4.00 hours ) 2018 November 24: Install painted parts (3.50 hours ) 2018 November 30: Install generator and breather (0.50 hours ) 2018 December 07: Install generator and breather (0.75 hours ) 2018 December 17: Brakes, spokes, old header pipes, etc. (3.00 hours ) 2018 December 18: Tires and lower from jack (4.00 hours ) 2018 December 19: Create wiring harness and misc (5.00 hours ) 2018 December 20: Install wiring harness (3.00 hours ) 2019 February 10: Rebuilt ignition switch (3.00 hours ) 2019 February 23: Install wiring harness (2.00 hours ) 2019 March 10: Airbox (1.00 hours ) 2019 September 02: Wiring (3.00 hours ) 2019 September 04: Mufflers, rear brake switch, generator cover (2.50 hours ) 2019 September 06: Install speedometer and dash (2.50 hours ) 2019 September 15: Spark plug wires (1.50 hours ) 2019 November 30: First start up (4.50 hours ) 2019 December 22: Reflector, shift lever, generator (4.00 hours ) 2019 December 23: Neutral switch, parking lights, generator (3.50 hours )