So next was to install all the missing motor bits – clutch basket, magneto, starter motor, oil tank, and then start on the radiator and at some point get my head around the wiring – that’s making me nervous….

Around about this point, I got my hands on a coating kit for Zinc Coating parts – a deposit on a XT500 I sold – so I started with some nuts & bolts and the left footpeg….
WINNER!!

So that obviously went on…

Last major job was the rear swingarm bearings – these are caged roller bearings and I was a little apprehensive bout pushing them in without a press and with my other favourite too – the hammer…..
Anyway, I cleaned up the damage caused by a rampant chain and no chain rails

Then in with the bearings – after heating the swingarm to Too-hot-to-handle temp and freezing the bearings and the gentle taps of the persuader using a socket as a guide and they were in!



Assembly went as planned, added the chain guard & rollers and then….
YUP – big moment for me - installed the rear shock…
And please note the shiny coated cap-bolts to hold the footpegs on…..

Whilst I was there, I added this…

And this…!

And then it was on to the wiring harness.

I decided to remove much of the old wrapping – old non-sticky insulation tape, and check and repair the wiring as needed – as it happened, not much was required – just a couple of wires worn through, repaired and then the whole harness was re-wrapped.

Please not the computer box indicated by the red arrow – this haunted me for a few hours on Sunday afternoon, the whole night of dreams and most of Monday at work – I could not for the life of me remember where I had removed it from, and by default, where to put it back….!

By using the Spark plug leads as reference points I worked out where it needed to be, and Google and looking at photos from where I stripped the bike, I worked out where to fasten it in – took more than one try….
People - I am getting excited......!!
