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Old 02-08-2016, 10:37 AM   #1
Truckin_Thumper
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the back fell off, help me fix it

20160206 150326 zpsvx0ycfqb

just kept falling off...

20160206 172635 zpspgjhgbjb

until it completely fell apart....

20160207 181625 zpsgznqyvjf



Actually, doing and oil change there was WAY too much metal for me to not do something.

Here is what I would LIKE to do:

Get a 2003 case and make it an e-start, not sure if it will bolt right up. Anyone know?

If not, it will get a complete overhaul, with new hotcams (auto decomp)

Needs a new steering stem, this one has been cross threaded. Maybe new clamps to accomodate 1 1/8" bars.

all new chassis bearings, swing arm and shock link, and steer head bearings.


Black paint: Frame, swingarm, engine.

White tank, white side plates, white headlight shroud

Blue plastics: Fenders

Blue wheels and hubs (probably just paint them), blue bits all over.

May anodize the radiators blue.
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Old 02-08-2016, 10:59 AM   #2
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been there done that!!! Have fun!!!!
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Old 02-08-2016, 11:02 AM   #3
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Quote:
Originally Posted by BYRDMAN View Post
been there done that!!! Have fun!!!!
repairing stuff is like a chore, restorations are fun
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Old 02-08-2016, 11:23 AM   #4
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Anodizing is rather cheap, might think about getting the hubs done too. Paint will chip after the first ride.
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Old 02-08-2016, 04:33 PM   #5
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Anodizing is my first choice for the aluminum bits. Paint the rest.

found the problem.


20160208 140919 zpsyxr4dtok

this chunk was wedeged on the counter balancer.

20160208 144332 zpsu0kymprn

Crank got pretty hot somewhere along the line. so I may just redo it while I am in there. New rings, probably keep the piston, head is in good shape.
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Old 02-08-2016, 04:53 PM   #6
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IS that the cam chain guide?
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Old 02-08-2016, 04:54 PM   #7
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Screw the Yammer, tell us about the Hinckleys.
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Old 02-08-2016, 05:12 PM   #8
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Quote:
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IS that the cam chain guide?
at one time, yes it WAS...LOL.

I dont have a gear puller to continue. Gotta find the right one...cheap.

I gotta find out what caused it to break.
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Old 02-08-2016, 05:15 PM   #9
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Quote:
Originally Posted by Volfy View Post
Screw the Yammer, tell us about the Hinckleys.
Three run...one dont...well....it does, but the tank is rusting so the fuel lines get clogged everytime.
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Old 02-08-2016, 07:15 PM   #10
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new crank......

20160208 1802411 zpsrqrrqoae
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Old 02-11-2016, 11:00 PM   #11
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Well.....everything is out of the cases. Except the roller/needle bearings.
Evidently a chunk of that stuff got into the roller and one of the crank bearings. I am here, not taking that chance.....all bearings to be R&R'd.

I really could speculate the cam chain was the culprit. Or, the guide just was fatigued and broke. Either way the results are the same.

I think this may take a few months to finish, as I am not sure about a few things to be done.

In order of " not in a rush" choices.

Should I motard this or what? So wheels are my last concern...BUT,I am going to do a complete restoration. New paint, some anodizing, all new plastics, headlight, and tank. Seat is in excellent shape.

I will paint the engine...black.....frame will be black, swing arm.....you guessed it black!
Blue fenders and shrouds. White tank. Blue and black seat. maybe a few blue bits on the motor....we'll see.

She might be too damned pretty to get dirty.

so, the next thing is new piston... stock or 444 kit? Might as well re-coat the liner while I am here.

Going with the Hotcams for exhaust...auto decomp FTW!

Head is in excellent shape.

Water pump will get rebuilt.......because.....why not.

I will start ordering parts tomorrow...LOL
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