Part 1:
My role in repairing the bike has let me work on many different areas and systems. At the beginning of the project, my main focus was on the electrical system including wiring connections, fuses, the battery, headlight, tail light, signal switches and lights. I started out my work on the bike by disconnecting the wires inside the headlight casing and labelling them alphabetically to be able to connect them when reassembling the bike.
Once all the wires were disconnected, I assisted Alec in removing the handlebars. After all the wires at the front of the bike had been removed, I moved to the back of the bike to disconnect and label wires. The next step was to remove the battery casing to remove the rust. Before the battery casing could come out, I had to remove multiple electrical components attached on to the outside of the casing. Sunjin and I then removed the tail lights, rear fender and rear wheel to get to the battery casing. After the casing was out, I turned my attention the electrical wiring.
All of the connections were corroded and in need of a cleaning so I began spraying them with a protective coating to remove and protect the connections. After the connections were clean, we found a new fuse holder for the fuses. I began to strip and solder the wires from the old fuse holder onto the new one with a solder gun. After soldering the wires onto the fuse box, I turned my attention to the carburetor.
The carburetor was a part of the project that I spent most of my time on. I began my work by spraying all the components with carburetor spray to clean out all the dirt and old fuel left in it. I then did research into upgrades for the carburetor to increase fuel efficiency and air to fuel ratio for a cleaner burn. Since the carburetor and the electrical ignition system are closely related, I also looked into upgrades for the electrical ignition system. We decided that an upgrade to a dual ignition coil, more powerful spark plugs and the Pamco electronic trigger system was needed. Keeping in mind the electric upgrades, DS and I decided on a package of components that would help the carburetor perform with the other upgraded electrical components. When the package arrived, I replaced the components that needed to be upgraded, as well as components that were old and worn (i.e. gaskets). With one more spray of carb cleaner to make sure all passageways were clean and clear, I began to rebuild the carburetor.
Once the carb was rebuilt, I helped Eric attach it to the engine. By then, Alec had finished painting the battery casing and so, we put that in. I installed the electrical wiring back onto the frame as well as the many electrical components that were on the battery casing. Once Sunjin had put the rear wheel, fender and signal lights on, I reconnected all the wires that I had previously disconnected. Once the handlebars and speedometer were on, I did the same for the front headlight casing.
When the battery arrived, we filled it up with acid and then put it into the battery casing. We then used the battery to check on all the electrical systems to make sure that they worked. We had some trouble with the signal lights but we soon found out it was due to a very poor connection. I began to take apart the electrical housing for the signal and sprayed some lube in to unseize it. Alec finished up the work so that the signal works again. I also cleaned, fixed and reattached the headlight onto the headlight casing. Right now, the only things that I have left to do is to replace the horn with the new one that we ordered in, and replace the right rear signal light because of the bad connection.
Once all the wires were disconnected, I assisted Alec in removing the handlebars. After all the wires at the front of the bike had been removed, I moved to the back of the bike to disconnect and label wires. The next step was to remove the battery casing to remove the rust. Before the battery casing could come out, I had to remove multiple electrical components attached on to the outside of the casing. Sunjin and I then removed the tail lights, rear fender and rear wheel to get to the battery casing. After the casing was out, I turned my attention the electrical wiring.
All of the connections were corroded and in need of a cleaning so I began spraying them with a protective coating to remove and protect the connections. After the connections were clean, we found a new fuse holder for the fuses. I began to strip and solder the wires from the old fuse holder onto the new one with a solder gun. After soldering the wires onto the fuse box, I turned my attention to the carburetor.
The carburetor was a part of the project that I spent most of my time on. I began my work by spraying all the components with carburetor spray to clean out all the dirt and old fuel left in it. I then did research into upgrades for the carburetor to increase fuel efficiency and air to fuel ratio for a cleaner burn. Since the carburetor and the electrical ignition system are closely related, I also looked into upgrades for the electrical ignition system. We decided that an upgrade to a dual ignition coil, more powerful spark plugs and the Pamco electronic trigger system was needed. Keeping in mind the electric upgrades, DS and I decided on a package of components that would help the carburetor perform with the other upgraded electrical components. When the package arrived, I replaced the components that needed to be upgraded, as well as components that were old and worn (i.e. gaskets). With one more spray of carb cleaner to make sure all passageways were clean and clear, I began to rebuild the carburetor.
Once the carb was rebuilt, I helped Eric attach it to the engine. By then, Alec had finished painting the battery casing and so, we put that in. I installed the electrical wiring back onto the frame as well as the many electrical components that were on the battery casing. Once Sunjin had put the rear wheel, fender and signal lights on, I reconnected all the wires that I had previously disconnected. Once the handlebars and speedometer were on, I did the same for the front headlight casing.
When the battery arrived, we filled it up with acid and then put it into the battery casing. We then used the battery to check on all the electrical systems to make sure that they worked. We had some trouble with the signal lights but we soon found out it was due to a very poor connection. I began to take apart the electrical housing for the signal and sprayed some lube in to unseize it. Alec finished up the work so that the signal works again. I also cleaned, fixed and reattached the headlight onto the headlight casing. Right now, the only things that I have left to do is to replace the horn with the new one that we ordered in, and replace the right rear signal light because of the bad connection.
Parts and Material List:
Carburetor:
Mikuni Carb Rebuild Kit (2) - $43.90
- 2 Gaskets
- Pilot Jet
- Small Round Main Jet
- Pilot Air Mixture Screw with Spring and O-Ring
- Choke Plunger and Washer
- Float Valve Assembly
Float Bowl Drain Plug - $7.00
- Pilot Jet
- Small Round Main Jet
- Pilot Air Mixture Screw with Spring and O-Ring
- Choke Plunger and Washer
- Float Valve Assembly
Float Bowl Drain Plug - $7.00
Jet Needle (2) - $11.90
Main Jet Sm. Round Type (2) - $5.95
5mm. Carb Float Bowl Screws (8) - $5.90
4mm. CV Carb Float Bowl Screws (8) - $4.50
Total Amount for Carburetor: $79.15
5mm. Carb Float Bowl Screws (8) - $5.90
4mm. CV Carb Float Bowl Screws (8) - $4.50
Total Amount for Carburetor: $79.15
Electrical:
12v motorcycle battery - $46.00
Fuses (4) - $1.00
Ignition Switch with Keys - $29.95
Pamco Ultimate High Output Ignition System - $224.95
Horn 12v - Chrome Face - $11.95
Button with Spring (for horn) - $5.95
Screws for Signal Housing (2) - $1.25
3 pc. Rear Signal Mount Kit (2) - $25.90
Signal Lamp Assy. Lens (2) - $35.90
Total Amount for Electrical: $382.85
Part 3:
The things that I have learned working on the bike are extensive. I have learned many things about electrical components and their uses as well as carburetors and the effect they have on fuel consumption and how the engine runs. My practical skills have increased as well. I know how to use different tools as well as make tools for some certain jobs. I have also learned how to be a leader in an area that I know a lot about and how to follow when they know more than I do. Since I am hoping to get into the automotive trade, this project has been very helpful for learning new things not just about automotives but about other vehicles as well.
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