Old swingarm and rear shock out, replacements in, along with new rear brakes.

 

Looking good! Great job with the clean up and 'technical' challenges.

 

Getting all of the details sorted out is half of the fun. (or more) Tonight I dove into the main wiring harness that I got for a bargain from eBay, ended up fixing 17 connections and only have the alternator/stator connector to button up once that arrives. Nothing glamorous in wiring, and I'm no expert, but it's nice to get it all sorted out and cleaned up.


Nearly all buttoned up

 

Opened the top end to check valve clearances and was pleasantly surprised that all of the valves are in spec. I have a new valve cover gasket to throw on as this one appeared to have a slight leak. Engine might end up in it's rightful place tonight...


Everything looks good in the top end...

 

Rear fender and wiring in, cleaned up the remaining bits of paint/overspray and got the engine in. All in all, a pretty good day.

 

Regulator/Rectifier wiring sorted, main fuse sorted, coils/plugs in and wired up, front fender mounted.

 

IMO, I'd look at replacing that R/R. They're notorious for failing.

 

I'll replace R/R at some point, using that one for now as I know it's good. Got a load of stuff done while the storm was blowing outside; new stator in, fuel pump/filter and hoses in, oil pressure sensor, temp sensor, coolant hoses, overflow tank, exhaust on, radiator on, water pump, ignition, front sensors, new start/stop/run switch, throttle housing and cables, choke cables, carbs, chain and sprocket, all wiring buttoned up, everything torqued down. Fixed the leaky fuel petcock and mounted the tank from the donor bike, installed the seat, and the bike is alive!


Oil pressure sensor in and wired up

Temp sensor wired up, H2O hose in, breather tube in

Starter in and wired up

Exhaust on and main coolant hose

Fuel pump, filter and hoses

Carbs, throttle and choke cables in

Air box on, radiator and H2O pump in

Tank, seat, chain/sprockets in, heel guard swapped

 

I've sorted out my speedo for this bike, all in a way that I can go back to original for '94 if I decide to sell the bike at some point. When I bought the bike it had a '96 wiring harness and gauges, and I had a sprocket-driven speed sensor from a box of parts that I picked up. Solution - Swap the '96 speedo into the '94 gauge housing, using wiring from the harness that I have. Currently in mock-up, but it's been tested and it works. This won't be a mod that everyone wants to do, as it requires some cutting on the '94 gauge housing, but this gauge housing was far from perfect in any case. Pink wire from the speed sensor goes to red on the back of the gauges, brown/black and green get spliced and connected to existing wiring on the back of the gauges for power and ground. (I made my wires long enough to connect to existing wires for the temp sensor)


Wiring sorted, waiting for shrink wrap and tape to button it up.

 

Wrapped up the speedo project, nice feature to have. Test fit the front cowl and the aftermarket bracket, decided to test fit the other plastic to make sure everything lines up before starting to get ready for paint.