2004#1 Re-Re-Store Project

[SupraSabre]

So yesterday, since we were getting rain into the late afternoon, I decided to work on the '04. It needed a new right fork seal (that I replaced a few years ago, and all the moving around caused it to leak) and replace the front tire, while I had the rim off. That took about three hours and some. But I got it done.

 

[SupraSabre]

And Yesterday I replaced the rear tire and installed new rear brake pads!







Next I need to bleed the rear brakes.

 

[SupraSabre]

Update: 10-8-2022:

I flushed out the SMC, rear brakes and the clutch. Next I'll be replacing all the locks so I'll have one key to fit all.

Then I'll be adding the '05 Red Tupperware.

 

[SupraSabre]

Update: I replaced the ignition switch and put the battery back in.

To replace the ignition switch, I had to drill out the screws that held it in.



And then I used some similar screws, they just didn't have "anti-back out" threads.



Also, the battery had been put into the 2010, so I pulled it out of the '10 and put in one of my new batteries in it, and put the other battery I bought for the '04, back in it.

They are different quality, that's why I swapped them back.

 

[SupraSabre]

Update 11-06-2022:

I swapped out the handle bars, switches and cables on the '04, with my 2012's that I removed when I put the cop bars on it. It's to help get that "New" look I'm trying for on the '04.
I also added a Heli Gen III raiser. The leftside switch is a new one, not the 12's.

I thought I had the tail cowl and the right side cover, but I cannot find them, so I'm going to have to buy a new rear cowl and the saddlebags covers and then get a right side cover and a front fender painted, since they no longer make them.

 

[Obo]

So with the half and half mix of '04 & '12 parts are you trying to make on '08?

 

[SupraSabre]

So with the half and half mix of '04 & '12 parts are you trying to make on '08?

None of the 2012 parts found on the '04 will make it a "later" model. These parts are those I have on hand in MUCH nicer condition, and since I'm putting on NOS tupperware (with a few exceptions) I might as well make the bike look as good as I can!

 

[SupraSabre]

Update 11-11-2022

I have been working on the Windshield mechanism this week:

One of my eBay units, that wasn't working.



The gear on the left came out of this broken unit. You can see why it wasn't working. Gear in the middle was made by one of the members a number of years ago, and the gear on the right is the gear that came with the Bike Quip gear/cable kit.



Original cable on the left, some places was scraped down to the metal. The Bike Quip replacement cable on the right.



Cutting off the old cable from the dog.



Cleaning the gunk out of the tubes.



Since it didn't have a crimper for the ferrules, I used epoxy to hold them on. I've done this for two other windshield mechanisms that I repaired in the past and haven't seen one fail yet.



Mounted and connected and it's working.


One thing I'm not really sure I like, the Bike Quip cables stick out pretty far when the windshield is in the down position (left side picture above), DON'T cut that part off. See below where I came up with a great solution!

 

[SMSW]

Naval Jelly, and some other acidic rust removers say on the label that after removing the rust, the steel must be protected immediately from moisture in the air. Rusting on this clean steel can begin almost immediately under damp or wet conditions. I'm not surprised your fuel tank rusted again after treating with the rust remover.

 

[SupraSabre]

Naval Jelly, and some other acidic rust removers say on the label that after removing the rust, the steel must be protected immediately from moisture in the air. Rusting on this clean steel can begin almost immediately under damp or wet conditions. I'm not surprised your fuel tank rusted again after treating with the rust remover.

As in the past with these windshield mechanisms, I used WD40 to clean them.
Haven't seen any rust on them yet?

 

[SupraSabre]

I came up with a solution for the Bike Quip long cables of the windshield mechanism.

I put tubing to protect them and any wires hanging near by. I'll see how that works out when I add the rest of the front end pieces.

 

[Andrew Shadow]

I came up with a solution for the Bike Quip long cables of the windshield mechanism.

I put tubing to protect them and any wires hanging near by. I'll see how that works out when I add the rest of the front end pieces.

Looks like a good solution.
You should bring this to the attention of BikeQuip. Maybe something he isn't aware of.

 

[SupraSabre]

Looks like a good solution.
You should bring this to the attention of BikeQuip. Maybe something he isn't aware of.

He states that he made the extra long, but I'm not sure if he aware of the possible issues they can cause. I have his "Survey" to yet fill out, I was waiting until I got it done, so I'll say something about them then. If I was really concerned, I could just cut them off.

 

[oude geit]

Did u make the bike quip cables same length of OEM??

 

[SupraSabre]

Did u make the bike quip cables same length of OEM??

No they are not and I did not.

As he states on his website, he left them long incase you ever needed to reuse them, the other (extended end) allows you to cut off the ferrules at the other end and then use them by placing a ferrule on it. This I could see if the bike fell over and broke one of the dog ears.

 

[oude geit]

So i guess the cables are the failure point. Added length to have 2 usages. I have a backup set i bought, but resources are a good thing, thanks for posting.

 

[SupraSabre]

So i guess the cables are the failure point. Added length to have 2 usages. I have a backup set i bought, but resources are a good thing, thanks for posting.

The cables and the gears are both failure points.

This particular unit I rebuilt failed because it was really dirty and the gear and cables had a hard time pulling the dogs through the rails. Even after cleaning the rails, the slides did not go through them without me pushing them. I found a couple of other rails and cleaned them, the same slides would go through with me just tilting the rails.

 

[Sadlsor]

Thanks for the step by step, these look good.

 

[SupraSabre]

More update:

I was sure I had all the pieces I needed with the exception of a front fender and topcase, but when I was going through my parts, I could not find the rear cowl and right side cover. I knew I didn't have the saddlebag covers in '05 red.

So I ordered the rear cowl and saddlebag covers. And the parts came in while we were gone.

I was able (although the garage was only 48F yesterday), to swap out the rear cowl, so now the bike will be the '05 red! .



Next, I'll start on the frontend.

 

[Obo]

So what's the plan when you have 3 complete ST's? Buy a 4th project?