I installed the transmission in the frame, mounted it to the engine block, connected it to the drive shaft, assembled the clutch throw-out mechanism, attached the speedometer cable, the neutral switch wiring and the foot shift.
I also installed the handlebars, perches, switch assemblies and routed the cables. Since I am converting the RS to and RT configuration, the switch wiring and cables are RT length.
This is the second time I have worked on rebuilding an airhead transmission. That should make it clear that I am an amateur, not a professional, when it comes to doing this work. I would not attempt to rebuild a transmission unless I have access to experienced, long time, airhead mechanics. I’m very fortunate to have access to three of them. And, I plan to continue rebuilding transmissions on my own projects, so the considerable investment in tools will get amortized over the future projects.
NOTE: I would not recommend that you rebuild your transmission unless you have completed multiple bike rebuilds, have invested in precision measurement tools and specialized transmission tools, and expect to rebuild multiple transmissions. The cost and risk are too high if you just plan to do one transmission. I would recommend you have your transmission rebuilt by a reputable builder such as Tom Cutter at Rubber Chicken Racing Garage in Pennsylvania, Matt Parkhouse ([email protected]) in Colorado, Bob Clement at Bob’s Motorwerks ([email protected]) in Montana, and Bud Proven at The Nickwackett Garage in Vermont.
This transmission has over 83,000 miles on it. That said, it was in good condition when I had the parts inspected by an airhead mechanic. So that’s a good thing.
I show how I route the main wiring harness after I installed the headlight shell. Previously I replaced the main harness with one from Euro MotoElectrics.
I completed installation of the fork and seat locks. I show the assembly of the seat latch mechanism and installation and also made a short video showing how I do the work.
I completed installing the rear end of the motorcycle. The fenders and rear lights will come in another post. You can read about how I did that work in these chapters of the “Assembly From The Frame Up” document: