Update kit install

[cardinal93]

Started the prep for the kit install tonight. Many thanks to @warp9.9 and @idk for loaning me some tools. Gonna honor Scott's request and wear the go pro tomorrow as we start the grunt work and try my hand at posting some how to videos for this one (assuming success )
No video tonight, but found the bike very easy to strip. Photo was about an hr in.
Prep work (order I went in):
Make sure bike is in neutral and disconnect the battery.
1. Remove any and all chrome/decorative covers between the tree and the rear fender. I covered the throttle bodies with tape after taking the filters off. Since my filters are huge and have to fit a certain way in my claw cut, I marked them and the throttle bar before removing.
2. Remove manifold and pipes (note, manual says rear section of pipes can be left on, but since I'm doing this in a home garage, why risk denting scratching?)
3. Drain and remove radiator
4. Remove neck covers and tank (easy 5 step process in manual, though I do recommend a second set of hands)
All told a little over 1.5 hrs by myself and I'm not what anyone would describe as a wrench turner.
As a note, since I don't do this often, every time I took a bolt or screw out, I put it back in after removing whatever it was holding. Don't want to end up missing some, putting them in the wrong holes (and puncturing radiators...don't laugh, I didn't do it, but it has been done ), etc.
I don't feel like the stripping requires too much explanation. I'll post tomorrow how it's progressing.

 

[1olbull]

Your motor looks to be in fine condition!
Good on ya for diving into this daunting tack!
I shall observe your adventure with great interest.

 

[Jag]

Is this preventive maintance procedure, or are you having problems?? Just curious. Like 1olbull I will be observing with great interest.

 

[Jeff Cameron]

Good start.....we needed a new project around here to all follow along with.

 

[cardinal93]

I've had the second gear issue (popping out under load) for a long time now. Been riding the past year without using second at all, so I'd say it's long overdue just didn't have the €2000 to pay a dealer to do it. I'll change the cam parts (as recommended) preventatively since the engine will already be out. Not doing the wiring updates since I've already resoldered my ignition module and installed the EB. I'll be adding keyless ignition during this mod and putting in a Bluetooth obdii to run instruments on a tablet. If it works well, may eventually remove the instrument displays altogether.

 

[Rocket Scientist]

OH NO, I'm re-living the nightmare

P.S. If you take your time and think things through it can actually be somewhat enjoyable. I have a little trick I'll share with you. I learned this the hard way. I use a weenie roasting stick or something similar in shape when removing the tranny gears from their shafts. Parts go directly off shaft onto stick. No guessing about the order and more importantly everything faces the correct direction. I put the tranny update in a 1983 Honda V-65 Magna for a fellow. Laid the gears, clips, washers etc. out on the bench in the order they came off. When it was time for reassembly, I had a small gear that had a slightly raised boss on one side but not the other. The boss wasn't even shown in the repair manual. Fortunately I was able to put the gear sets together and by looking at the alignments, tell which way it went. Didn't care for that panicked feeling. Been using the stick method since.

 

[idk]

That is a good idea.

 

[warp9.9]

It aint done yet ? Come on this is where you go into time lapse mode like this old house so it is completed during the commercial break

 

[Triple Trouble]

When taking engine covers off I use a cereal box and place the screws though the box in the exact pattern they are on the bike. That way if the lengths or diameters are different it is not a problem as they go back in exactly the same position. A camera is also helpful.

 

[idk]

A few disposable baking trays are useful for putting parts in. Use a different tray for different sections. That way all the parts are together, and you will know if you left something off.