71 xlch : 05

Brake cable guide has been welded on.



Took a few glamor shots. Notice the Cycle Shack pipes I scored for a few bucks shipped. They aren't in perfect condition, but at least they provide some back pressure and noise reduction. The drag pipes were just stoopid loud.













Here's the wiring diagram, but I didn't use fuses for the lights.



Blew the front head gasket last night putting around the neighborhood. I don't think this bike likes me too much. Going to replace that this evening and hopefully work my way into it's good graces.

71 xlch : 04

Almost finished. The bike still needs some tuning, wiring in the lights, and finishing the front brake cable holder. It does run again though, and so far shifts properly.







Brake stay minus cable holder and cable pinch assembly.

71 xlch : 03

Sometimes projects can take a turn that is completely unexpected. For instance, maybe you decide to take the front sprocket off and take a look around. By chance alone, you just happen to notice the mainshaft that should be riding on needle bearings, is in fact riding on thin air. Is it luck that I found it now before hitting the road? Yes. Still sucks though. Enough whining, here's some pics.

Ghost bearings.





Apparently someone previously reinforced the countershaft bearing area. This support is probably the only reason the trans didn't destroy itself.





The mainshaft would bend under load and rub against the bearing race. You can clearly see where the two tried to get frisky.





Empty.



Fortunately I found an NOS mainshaft for about the same cost as the cheaper aftermarket ones. The bearings, race, seals, etc. added in put the total cost to $186.21 including shipping. Not bad at all.

Going back together.





Jump ahead a bit, and I started to make a battery mount for the YT4B-BS I got off of ebay for less than $20 shipped.





Then a bracket to locate the coil off the top motor mount. Don't mind the wires, they were replaced last night for some at the proper lengths.



I'm wrapping up the front brake anchor and cable setup, then it's on to wiring and adding oil. Yeehaw!