S90: Airbox #2 Continued

I'd almost given up on the second airbox, since it seemed impossible to get the stuck screw out without also damaging the tab itself. 

But once again, the 4-week break from wrenching proved useful for problem solving.  I'd realized I could just clamp the tab down to provide enough support to take the hammering from the impact driver.  So I threw two clamps on the tab, then put the clamps themselves into the vice and Presto!

With just a couple whacks the screw freed up, and I turned most of it out by hand.  Plus, the tab actually got bent back in the right direction and looks pretty close to where it ought to be now.

S90: My Kindgom for Ring Pliers!

Hadn't been down to the garage in a month (a case of life getting in the way of hobbies), but I think that allowed time for some creative problem solving to percolate around in my brain.

Problem One was the fact that this clutch housing didn't have the little notches in it that allows you to use the basket holder to lock it in place while you remove the locknut.  I tried the penny in the gears trick recommended by Clymer.  But the first penny just got chomped in two, while the second one seemed to lock the gear, but not the clutch and therefore I still couldn't turn the nut.

But the solution was obvious: just put a very big piece of metal through the con-rod and lock the whole thing up.  At first I tried some wrenches, but they were getting bent.  Finally this old cheap, but very big screwdriver did the trick.

But after enjoying that success for a few minutes, I was immediately stymied by the fact that I had no ring pliers to get the primary gear off.  It seems simple enough to do it without the right tool, but short of cutting it off, I couldn't get the leverage to remove it.  Finally decided it was a good excuse to get a new tool and ordered a Lisle snap ring plier from Amazon.

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.