I thought I would provide a progress report on this project.  There has been a lapse in my posts.  My wife and I spend six weeks in Europe (all of June) with three of those weeks engaged in “applied motorcycling” as we rode on two guided motorcycle tours.  The first was in eastern Europe riding in parts of the former Yugoslavia, Bulgaria and Albania. Here’s my trip report, A Motorcycle Tour of Eastern Europe: “Combat Touring” in the Balkans.  And the second was in the Pyrenees and I’ll be posting a trip report on that ride soon.

After returning, there were a number of things to get on top of including a major landscaping project, and all of a sudden, it’s early August. I finally got back into the shop this week and started by reviewing what I had completed so far (see the work plan below).

I was able to remove the clutch and flywheel just before I left for Europe. Upon inspection of the clutch, I decided to replace it. I ordered the parts from Tom Cutter at Rubber Chicken Racing Garage and they came in just before I left. I’ll start work on replacing the rear main seal and oil pump cover o-ring and then getting the flywheel and clutch back into the engine block and I’ll post a web page on that work soon.

I decided to go back to the carburetors and replace the screws on the top covers with new stainless steel ones. Some of the slots in the screws had been enlarged so time to get that taken care of.  And, I wanted to add the spring on top of the slide that was included staring in 1977. I’ve heard this improves smoothness and I did the same upgrade to the carburetors in the R75/6 project.  I’ll update the carburetor rebuild page to include this.

Here’s the spring and how I installed it.

I also tried a little trick to ensure the throttle screws on both carburetors are just touching the tab on the throttle shaft. I slipped a piece of paper between the tab and the top of the adjusting screw and then tightened the screw until I could just feel the drag on the paper. I always have a hard time ensuring the screws are evenly touching the tab when the carburetors are mounted, so this way they are even before I install them.

Here is the progress on the task list so far.  The good news is there are more check marks since the last report in March.  But, there are still quite a few tasks to keep me busy 🙂

Front Wheel
√	Remove fairing
		Repair fairing
		Stip fairing
		Paint faring
√	Remove fender
		Strip fender
		Paint fender
√	Remove brake cable
√	Remove front wheel
		Remove tire and tube
		Remove spokes
		Clean & polish wheel and rim
		Install new spokes OR clean old and install
√	Inspect brakes
		Replace brake shoes
	Inspect wheel bearings
		Inspect, Replace wheel bearings if needed
		Grease wheel bearings
	Replace tire and tube
	Balance
	Mount
	Replace brake cable
	Adjust front brake
Rear Wheel
√	Remove rear fender
		Strip rear fender
		Paint rear fender
√	Remove rear wheel
		Remove tire and tube
		Remove spokes
		Clean & polish wheel and rim
		Install new spokes OR clean old and install
√	Remove Rear Drive
√		Clean & Polish
√	Inspect rear brake shoes
		Replace brake shoes
	Inspect wheel bearings
		Inspect, Replace wheel bearings if needed
		Grease wheel bearings
	Clean & polish wheel and  rim
	Install new spokes
	Replace tire and tube
	Balance
	Install rear wheel
		Lube rear drive splines
	Adjust brakes
Front Fork
√	Remove handlebars
√	Remove headlight
√		Clean and repair paint
		Install headlight
√	Remove triple clamp
√	Inspect steering head bearings
√		Replace steering head bearings
√		Install new bearings/races
√	Reassemble steering head
	Install and align forks
√	Drain and Remove forks
√	Disassemble forks
√	Replace all rubber o-rings, bushings, etc.
√	Reassemble forks
Controls
√	Remove rider foot pads
√	Remove brake cable
√	Remove clutch cable
√	Remove throttle cables
√	Remove choke cables
√	Remove handlebar grips
√	Remove handlebar controls
√		Powder coat handle bar perches
√		Strip switch brackets
√		Paint switch brackets
√	Remove handle bars
√		Replace handlebars
√	Polish mirrors
√	Polish control  levers
	Install handle bars
	Install handlebar controls
	Install brake cable
	Install clutch cable
	Install throttle cable
	Install handlebar grips
Engine, Clutch
√	Remove Carbs
√		Rebuild carbs
√		Clean & polish air tubes
√		Clean & polish hose clamps
√	Remove air box halfs
√		Clean and polish air box halfs
√	Remove starter cover
√		Clean and polish starter cover
√	Remove valve cover
√	Remove head
√	Remove cylinder
√	Rebuild head
√	Remove piston
√	Remove rings
√	Remove engine
√	Clean piston
√	Measure cylinder bore
√	Gap new rings
√	Install new rings
√	Remove clutch
√		Inspect clutch for wear and condition
		Replace clutch
√	Remove flywheel
√		Refresh paint on timing marks
	Replace Rear Main Seal
		Repair Oil Leak in Flywheel Bolt Hole
	Replace Oil Pump Seal
	Install flywheel
	Assemble & Install clutch
	Remove oil pan
		Clean & polish oil pan
		Inspect screen
		Install new pan gasket
	Replace cam shaft seal
	Clean and polish engine case
√		Clean top cover
		Clean front cover
	Install cylinder base gasket
	Install push rod tube bushings
	Install cylinders
	Install pistons
	Install head gasket
	Install heads
	Set valves
	Install valve cover gasket
	Install valve covers
	Install carbs
	Balance carbs
	Set timing
Transmission
√	Remove transmission
√		Clean and inspect
		Replace clutch throw-out felt, gaskets, seals
		Lube splines
	Install transmission
		Install new speedometer cable
		Install new clutch cable
Tank
√	Remove tank
		Strip tank
		Paint tank
√	Remove petcocks
√		Rebuild petcocks
	Install petcocks
	Install tank
	install new fuel lines
	Install new air cleaner
	Install air box and starter cover
Frame
√	Remove seat
√	Remove side panes
		Strip and paint side panels (Blue Stripes)
√	Remove front foot pegs
√		Polish pegs
		Install footpeg rubbers
√	Remove rear foot pegs
√		Polish pegs
		Install footpeg rubbers
√	Remove side stand
√		Clean, polish side stand
√	Remove center stand
√	Remove shocks
√		Clean and polish shocks
√		Clean and polish shock covers
√		Powder coat shock springs
√	Remove battery box
√		Powder coat battery box
√	Remove battery
		Replace battery
		Replace (+) and (-) cables
√	Remove rear frame
√		Powder coat rear frame
√	Remove Rear Turn Signals & Tail light
√		Clean and polish turn signals
√		Strip tail light
		Paint tail light
√		Replace turn signal stalk
√	Remove swing arm
√		Powder coat swing arm
√		Replace swing arm bearings
√	Remove electrics
√	Remove wiring harness
√	Remove headlight shell
√	Powder coat frame
√	Powder coat sub-frame
√	Powder coat battery box
√	Powder coat license plate braket
√	Powder coat center stand
√	Powder coat swing arm
	Assemble center stand
	Assemble electrics
	Mount wiring harness
	Mount engine in frame
		Mount side stand
		Assemble oil filter and cover
	Mount transmission to engine
		Lube output shaft splines
	Mount swing arm
	Mount rear drive
	Assemble rear frame
	Assemble shocks
	Mount Seat