2004#1 Re-Re-Store Project

[SupraSabre]

Once I got my 2010's clutch, clutch slave & waterpump replaced and put the bike back together, I'm now using it for my commute since I can't seem to keep the 2004#2 from having problems.

This allowed me to move the 2004#1 into my MC shed, which has been in the other shed, right at 4 years.

So far I've tore off all the tupperware and drained and pulled the fuel pump from the lower tank.



The lower tank had a bunch of rust, along with the fuel pump!



So, today I took the vacuum to it, cleaned out all the loose stuff, then took some Naval Jelly to the rust. It cleaned out pretty good!



I'll check it again tomorrow and see if I need to repeat the NJ, but it's looking good.

Next, I'll add some gas and put my fuel pump I bought off ebay a few weeks ago and get it running, before removing the coolant, radiator and frontcover, to replace the waterpump!

I'll add pictures as I'm re-restoring it!

 

[ToddC]

Keep those pic coming.....
Can't believe you need to do all that work to the '10 already. But it has been a couple years already......wow.

ToddC

 

[technotony007]

looks a good job , what is naval jelly ????

 

[SupraSabre]

looks a good job , what is naval jelly ????

It's a rust remover! LOCTITE-16-oz-Rust-Remover

 

[technotony007]

Nice one ,thanks for sharing that. never seen that stuff before , think inwill have to see if they sell the naval jelly accross the pond over here....

It's a rust remover! LOCTITE-16-oz-Rust-Remover

 

[granlund1]

EvapoRust works well also.

 

[SupraSabre]

Two months later and I haven't been able to do a thing to this poor bike! It's still sitting on my lift, waiting for me to get back to it! 4:

 

[SupraSabre]

Two months later and I haven't been able to do a thing to this poor bike! It's still sitting on my lift, waiting for me to get back to it! 4:

And here it is August and the bike is still sitting in the same shape! 4:

Someday....

 

[ST_Jim]

And here it is August and the bike is still sitting in the same shape! 4:

Someday....

Life happens!

I haven't even started my bike in months, and it runs. (Long story, don't ask.)

 

[SupraSabre]

... (Long story, don't ask.)

Okay, I won't! 4:

 

[SupraSabre]

I made Progress!

Yesterday I decided to get back to the '04#1's waterpump replacement. So I removed the front tire, the fender, front forks and radiator!





I need to check my parts available a see what I'll need to order so I can replace the clutch, waterpump, clutch slave, all coolant hoses, rebuild the forks, etc.

Also, I opened up the lower tank/fuel pump and checked the lower tank for rust and there wasn't any! So my de-rusting of over a year ago has paid off!

 

[SupraSabre]

Just ordered all the parts to "mechanically" get the 2004#1 back into shape. Once I do that, I'll start looking at what tupperware to install on it.

At this time, I'm really thinking moving the black from the 2012 to it, and then mount all the NEW parts to the 2012!

Then I would have a '04 - Black, '10 Blue and a '12 Red!

That should keep you all confused!

 

[SupraSabre]

My $450 worth of parts came in today! Now all I need is some time so I can get to it!

 

[Al Gully]

My $450 worth of parts came in today! Now all I need is some time so I can get to it!

My $350 worth of parts arrived yesterday from partzilla. Now all I need is some time so I can get to it!
Sounds like where singing the same tune
Wife's birthday today

 

[MaxPete]

Wife's birthday today

Well, if you know whats good for you young man......

 

[Al Gully]

Well, if you know whats good for you young man......

You can say that again too, it's Bob's birthday too

 

[SupraSabre]

You can say that again too, it's Bob's birthday too

And we had quite the group here last night! Three of my sons with most of their families!

 

[SMSW]

looks a good job , what is naval jelly ????

I believe it is a gelled phosphoric acid. Not positive, tho.

 

[SupraSabre]

Well, it only took 7 more months to get anymore done.

This last weekend I removed the exhaust & headers, the centerstand, oil cooler and the clutch slave.

Next weekend, I'll start removing the front cover, so I can replace the waterpump, the clutch plates, the clutch slave, the oil seal in the rear cover to the clutch slave. Then, I'll start on replacing all of the coolant hoses. Which is why I removed the oil cooler, it is easy to replace those hoses when you drop it down.

I'll see if I can remember to take some pictures tonight or tomorrow night and post them!

 

[SupraSabre]

Okay, I finished the r&r on the Waterpump, clutch & clutch slave. Digging out that clutch oil seal was a real bear! Almost as bad as the front cover & clutch slave gaskets!

Here are some pictures: