2018 December 09: Crab the frame Updated: 2018 December 09
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The rear clutch seal has been leaking a lot. Fed up with the mess, I crabbed the frame and removed the rear cover from the transmission. After heating the rear cover such that the bearings would drop out (rather than needing to be pulled), I discovered that the spring which fits around the lip of the seal had broken. Time to order new parts.
At the same time, I noted how horrible my wiring was. I installed this wiring before I began making (and selling) my own wiring harnesses. Time for a complete re-wire! So, I removed all of the original wiring.
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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