S90: Bottom End #2

Couldn't resist grabbing this complete bottom end, since I knew at the very least I needed clutch parts and a primary driven gear - which individually would have added up to more than I paid for this.  Plus, the main benefit is that I can go to town tearing this thing apart purely for the education of it.

As expected, all the screws were frozen, but as usual the Lisle and the Dremel took care of those.  But I think the tough part will just be separating the halves, and I'm eager to see how much of an effort that will turn out to be.

If it's impossible to open the crankcase without destroying it, I'd have to consider taking it to a shop to have it done when I do one that really matters.

S90: Electrical Mock-Up

Finally finished the electrical mock-up box for the S90.  This box uses the real main wiring harness substituting test lights and switches for everything from the ignition coil to the turn signals.  The key ignition is lifted off the CM91.

S90: Skid Plate Painting Test

After closer inspection, I realized the S90's skid plate is actually a custom job.  Another testament to the shop skills of the mysterious previous owner who tried to turn the bike into a trail machine.  I'm not sure if I'll ever use it or not, but it seemed like a perfect piece to use to practice with rattle cans.

This side of the plate was sanded using the new sanding disc.  Then I did about four coats of Krylon's Rust Tough black paint followed by three coats of Dupli-Color Clearcoat.

The intention wasn't to get a "finished" look, but just a "working" paint job.  Something that looks decent and more importantly, protects the metal until the bike eventually gets a professional paint job.

Before...

 

And after...

S90: Fifteen Year-Old Rubber

Apparently after sitting for two decades, the rubber knee pads turn into hard plastic.  Removing them from the tank covers was an exercise in brute force and three different pliers.

S90: Fifteen Year-Old Rust

Not exactly sure what this is.  I think it's a mix of old gas and rust.  I literally had to shake it out of the original tank.

S90: Grips Installed

Pair of new grips arrived this week.  For some reason I thought these would be a real hassle to get installed.  Turned out to be a snap; had them both on within minutes.

Tools: Sanding Disc

This little contraption worked better than I'd expected actually.  You can bend the yellow plastic holder to navigate curves and bumps.

S90: Handlebars Coming Together

Put in a nice long session today full of odd jobs, but mostly centered around getting the headlight and handlebars back together after waiting on new parts, painting, and cleaning.

The newly painted plastic headlight case goes back into place.  Painting this piece was more an excuse to start figuring our my rattle can techniques than a serious painting effort. 

Next the headlight assembly and speedo go back in.  You'll note the rough edge at the bottom of the speedo's chrome part.  Normally you'd crimp that back into place but I purposefully left it that way so that it would be easy to take apart again if I need to.  I'm not 100% sure that all the fixes are complete to it, so I figured I'd leave it easy-to-open until I'm sure it won't need to come apart again.

The switches go back on, both with new levers (the old left side was bent, the old right was broken at the tip).  New throttle and brake cable.  New cable adjusters.

Unfortunately, the throttle holder on the new cable didn't quite fit the dimensions of these handlebars, so I switched it out with the original one.  This is a shot of the old one, which was just a tad too small.

S90: Speedo Update 2

Here's a shot of the speedo all cleaned up and with black touch up paint around the 40mph mark.  Not quite a perfect match on paint, but better than the chipping.