2009 April 21: Rear drive (2.00 hours ) Updated: 2009 April 21
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Finished setting the bearings on the pinion carrier (needed to remove one 0.1 mm shim.
Checked the interface of the pinion and crown gears with some blue paste. Everything looks fine there, and since the teeth already look very good, I reassembled without making any critical shimming adjustments to either the crown wheel or pinion.
Fit a new inner (larger) seal.
Fit new gaskets (greased on both sides for easy future removal, as I do on nearly all gaskets).
Cover torqued to 18 foot pounds.
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Additional entries for this project
2008 February 18: Purchase and disassembly (3.00 hours ) 2008 February 19: Disassembly (2.00 hours ) 2008 February 21: Disassembly (5.50 hours ) 2008 February 23: Disassembly and cleaning (1.50 hours ) 2008 February 24: Cleaning (2.50 hours ) 2008 February 25: Disassembly and Cleaning (1.00 hours ) 2008 February 26: Clean up (0.75 hours ) 2008 February 27: Measuring (1.50 hours ) 2008 February 28: Cleaning (0.25 hours ) 2008 February 29: Polishing (0.75 hours ) 2008 March 01: Measuring and cleaning (4.50 hours ) 2008 March 03: Disassembly (2.50 hours ) 2008 March 05: Shipping, organization, and disassembly (0.50 hours ) 2008 March 06: Powder coat prep (0.25 hours ) 2008 March 07: Trip to powder coater, disassembly (3.00 hours ) 2008 March 08: Disassembly, cleaning, measuring (5.00 hours ) 2008 March 12: Disassembly, cleaning (3.00 hours ) 2008 March 13: Order parts (0.00 hours ) 2008 March 14: Fixing (2.00 hours ) 2008 May 07: Assembly (0.50 hours ) 2008 May 08: Assembly (0.50 hours ) 2008 May 10: Clean and paint (0.75 hours ) 2008 May 11: Paint and powder coat clean up (2.00 hours ) 2008 May 26: Acid cleaning and engine assembly and tire mounting (4.00 hours ) 2008 May 27: Tire mounting (0.50 hours ) 2008 June 01: Wheel assembly (3.25 hours ) 2008 June 02: Wheel assembly (0.25 hours ) 2008 June 04: Engine assembly (2.50 hours ) 2008 July 14: Engine assembly (0.50 hours ) 2008 July 20: Brakes (1.00 hours ) 2008 July 22: Brakes and polishing (2.50 hours ) 2008 July 24: Transmission (2.00 hours ) 2008 July 26: Transmission (4.00 hours ) 2008 July 27: Engine and transmission (5.00 hours ) 2008 July 28: Frame and swing arm (2.00 hours ) 2008 August 14: Starter (2.00 hours ) 2008 October 07: Pistons and cleaning (1.00 hours ) 2008 October 08: Heads and cleaning (1.25 hours ) 2008 October 09: Cleaning (0.50 hours ) 2008 October 10: Carburetor assembly (2.00 hours ) 2008 October 13: Carburetor assembly (0.50 hours ) 2008 October 14: Cleaning and polishing (1.50 hours ) 2008 October 16: Cleaning and polishing (0.25 hours ) 2008 October 17: Cleaning and polishing (0.25 hours ) 2008 October 18: Alternator testing and assembly (0.50 hours ) 2008 October 22: Cleaning heads (1.25 hours ) 2008 October 23: Rear shocks (1.75 hours ) 2008 October 24: Rear shocks (1.75 hours ) 2008 October 25: Pistons and front forks (4.00 hours ) 2008 October 29: Rear shocks (0.25 hours ) 2008 November 06: Pistons (0.00 hours ) 2008 November 22: Pistons and cylinders (2.00 hours ) 2008 November 23: Pistons and cylinders (1.00 hours ) 2008 December 04: Pistons and cylinders (0.50 hours ) 2008 December 05: Pistons and cylinders (1.00 hours ) 2008 December 20: Brakes (1.50 hours ) 2008 December 22: Brakes (2.00 hours ) 2009 February 05: Assembly (2.50 hours ) 2009 February 06: Zinc plating (2.00 hours ) 2009 February 07: Assembly (1.35 hours ) 2009 February 08: Zinc plating (1.50 hours ) 2009 February 10: Miscellaneous cleaning and assembly (3.50 hours ) 2009 February 13: Miscellaneous cleaning and assembly (5.00 hours ) 2009 February 14: Polishing (1.50 hours ) 2009 February 19: Cleaning and assembly (3.00 hours ) 2009 February 20: Polishing (0.50 hours ) 2009 March 13: Polishing and assembly (3.00 hours ) 2009 March 14: Ignition switch (2.00 hours ) 2009 April 13: Front forks (2.00 hours ) 2009 April 15: Front forks (0.50 hours ) 2009 April 16: Front forks (0.25 hours ) 2009 April 20: Rear drive (2.25 hours ) 2009 April 21: Rear drive (2.00 hours ) 2009 April 28: Front forks and rear drive (2.00 hours ) 2009 May 04: Front fender and brakes (1.25 hours ) 2009 May 07: Tank (1.00 hours ) 2009 May 14: Front fender, wheels, brake calipers (1.00 hours ) 2009 May 16: Tank and hydraulic hoses (1.50 hours ) 2009 May 17: Hydraulic hoses and brake lines (2.00 hours ) 2009 May 23: Fuel tank (2.00 hours ) 2009 August 22: Wiring (1.75 hours ) 2009 August 29: Wiring (2.00 hours ) 2009 September 04: Wiring (1.00 hours ) 2009 September 05: Wiring (1.00 hours ) 2009 October 18: Wiring (2.50 hours ) 2009 October 24: Wiring (1.00 hours ) 2009 October 29: Seat (0.50 hours ) 2009 October 30: Brakes and wiring (2.50 hours ) 2009 November 02: Brakes (2.50 hours ) 2009 November 05: Brakes, seat pan, coils (3.00 hours ) 2009 November 05: Transmission hoses (0.50 hours ) 2009 November 06: Wiring (3.50 hours ) 2009 November 07: Wiring and rear turn signals (3.00 hours ) 2009 November 14: Wiring and headlights and front turn signals (0.50 hours ) 2009 November 20: Wiring and headlights and front turn signals (3.00 hours ) 2009 November 21: Coils (1.00 hours ) 2009 November 22: Coils and timing (3.00 hours ) 2009 November 23: Coils and brakes (2.00 hours ) 2009 November 24: Exhaust (0.25 hours ) 2009 November 25: Exhaust and initial start up (2.00 hours ) 2009 November 29: Wiring (0.50 hours ) 2009 December 05: Wiring (0.50 hours ) 2009 December 14: Wiring (2.00 hours ) 2009 December 15: Heads and oil line (2.00 hours ) 2009 December 16: Oil line (0.25 hours ) 2010 January 30: Throttle and start button (1.00 hours ) 2010 February 10: Paint (0.00 hours ) 2010 March 29: Paint (0.00 hours ) 2010 June 02: Reflectors (0.25 hours ) 2010 June 03: Foot board rubber mats, brake lines, etc. (2.00 hours ) 2010 June 13: Seat (2.00 hours ) 2010 June 14: Seat (0.25 hours ) 2010 June 15: Seat (0.50 hours ) 2010 June 16: Seat (0.25 hours ) 2010 June 23: Tank, etc (2.00 hours ) 2010 July 27: FINISHED! 2011 September 26: Photos 2012 October 07: Convert compression 2012 December 14: I-Convert breather 2012 December 20: Repaired Speedometer for I-Convert 2013 January 07: Re: Repaired Speedometer for I-Convert 2013 February 09: Re: Repaired Speedometer for I-Convert 2013 February 17: Scientific Test 2 complete 2013 February 28: More progress on the I-Convert 2014 May 31: Breather Fun 2014 November 07: Convert Breather 2015 February 15: Remove pistons and cylinders 2015 February 17: Ordered new Gilardoni pistons and cylinders 2015 February 21: Installed new Gilardoni pistons and cylinders 2015 March 08: Convert follow-up 2018 December 09: Crab the frame 2018 December 17: Reassembly 2018 December 18: Headlight 2018 December 21: Wiring