Work In Progress

Haven't had an overall shot of the work in progress for a while, so here it is. I've got the handlebars and controls mostly back on, and the big task at this point is installing all new cables. I put the tank in place to make sure all the wiring and cables avoid hitting spots they shouldn't.

Also at this point, the carbs are back in place, since I'm done adjusting the top end (except for a teeny problem on the right side I'll discuss later). Back to work!

Magura Grip Wedges!

When taking apart the handlebar control assemblies, be VERY careful not to lose the Magura grip wedges. These are tiny, rectangular pieces with ridges that prevent the assembly from rotating on the handlebar when tightened. Note that the one pictured has been cleaned. When you first take these apart, they may be black from age and hard to see, and can easily get lost. New ones (32 72 2 072 223) run about ten bucks each!

Handlebar Control Bits

The control housings on the left and right handlebars were intact and not damaged, and really just needed to be painted. Since I had already sent the larger pieces out to be powder coated, I decided to prep and paint these small components myself. The body shop working on the pinstriping and painting suggested I clean the parts with a solvent and then paint them with multiple coats of trim black. I think several manufacturers make a trim black product. It's basically an aerosol used for painting exterior trim bits on cars and comes in a matte finish.

Front Fork Filler Caps

After removing the handlebars and top fork nut, the two filler caps can be removed. For this, you either need a special tool or you can use two drill bits or allen wrenches in the holes with a lever of some sort between them.

If you happen to have the original toolkit from the bike, you should have one of these wrenches. I ordered a fork cap pin wrench (71 11 1 237 858) from Hucky's. It wasn't very expensive, and it's the easiest way to get it back on tight when reassembling.

I Fought the Lock and the Lock Won

The fork lock is one of several items you'll need to remove from the frame before it can be powder coated. This is what mine looked like before I attempted to remove it...pretty harmless, huh? The problem, of course, is that I didn't have the key. If you're in the same boat, do yourself a big favor and read Duane Ausherman's article on fork steering lock removal. I didn't know about this article until it was too late, and I'm too ashamed to post the photos of what the lock looked like two days and three drill bits later. It wasn't pretty.