990 Rebuild Part Something Or Other

You know a build is near the end when you can't remember when you started it any longer. Well, I'm there and more, but am almost through. Save a couple of unforeseeable issues, I should be done in a few days...that's called foreshadowing. I learnt it from great literature and such.

Anyhow, with the throttle bodies installed, it was time for some finishing touches. First up is the chain. After mulling over reusing the chain that came on the bike, I decided to use my cool DID gold chain. I mean, how are people going to know I'm really cool if I don't sport some bling? After measuring the old chain, I went at it. I had to cut the new chain down two links. That means out comes both the chain tool to install it and the grinder to grind off the extra link.

Yup, too long.

After a bit of mayhem with the grinder, time for the chain tool to press out the extra link

Of course, the damn pin arbor broke, but I was prepared with an extra and got the offending pin out and the link off

The I lined the two chain ends up to fit the new master

Once greased up and installed, I used the chain tool to first press on the side plate

I used a caliper to measure how far I pressed on the new plate. It needs ot be the same as the other links.

Then I reset the chain to to rivet the pins. You want to flare the new master's pins 0.4-0.7mm. I aimed for 0.5mm.

Then it was onto the front sprocket. With the chain on, I could put the bike in first gear and torque the fixing nut to 100nm.

Then I bent down the safety washer so the nut wouldn't back off.

Finally, I installed the sprocket guard as well as the side stand sensor.

Then I installed the shifter and made sure to check the torque settings so it would stay on

All done down there....well, until I get the shift shaft seal I ordered, but I will get to that later.

Then it was time to add coolant and bleed the system..Engine Ice for hot Arizona

I borrowed an engine hoist from a buddy to make the job easy

I first added the coolant until it was topped off, then I raised the front end 20 inches to burp it

I even have the right funnel for the job

First you bleed the system at the water pump bleed screw, then you move to the radiator bleed screw to finish the job. If you don't do this step (the whole bleed step that is), then you can have bubbles of air in the system that will cause the bike to overheat and blow coolant out of the overflow.

Once the bubbles stop coming out of the upper bleed screw, you close it off, lower the bike and top of the coolant and you're done...easy with the hoist.

Then it was onto the oil.

I used a different funnel for the oil...I have lots of funnels.

I poured 2 liters in and then another 500ml to start with. The oil dipstick read past full at that point, but I knew it had to slowly drain into the lower part of the engine over night, so I lefit it at that for the moment.

Well, that left me with the left hand fuel tank. I wanted to test start the bike and to that end, I had been charging the battery for awhile to get it topped up.

While that was charging, I installed the tank.

It's really straight forward. Three bolts hold it on after you hook up the fuel line, fuel pump power and fuel level connectors.

Then I went ahead and flashed out for some fresh fuel and a couple of new bolts for the tanks as the old ones were pretty corroded. Ace is a great place for bolts. I buy lots of fasteners there. I like shiny bolts. When I got home, I installed the radiator guard and the now fully charged battery.

That hose is the crossover hose for the second tank. It allows both tanks to self equalize (along with the upper crossover line).

Once that was done I decided to fire it up. Now, by then it was late and I really wanted to know if there were issues with the work I had done along the way. Did I screw up the throttle bodies? Were the valves really in spec? Had I messed up the fuel pump? My heart almost stopped when the battery cranked and cranked and nothing happened for 10-15 seconds. I stopped, gave it a little throttle and hit it again...nothing but a small stumble. I always try at least three times, good thing too, because on the third attempt, the bike (eventually) roared to life. Talk about a load of pressure released. I stepped back as the bike idled stronger and stronger every minute. I let it go for several minutes waiting to see if it would die or overheat. The worst that happened was the fuel connector between the tank and bike leaked for a few minutes until the o ring swelled back up and sealed properly. I was so pumped I didn't take a picture or video. Instead, I called the old owner and let him listen to it. We chatted for a few minutes before I heard the most horrible screech coming from the bike. I shut it off right away, but it continued after I killed the engine....WTF?! Closer inspection showed that the clamp on the right side oil breather tube was rubbing the radiator fan. No problem, I fixed that in a jiff and restarted the bike. Cool, two starts in one day. The bike hadn't run in almost three months, so I was extremely pleased. I was so pleased in fact, that I went for a very short ride up the street and back. MAN! it all worked.

I went inside after putting everything away and left a clean piece of cardboard under the bike to check for leaks over night. Anyhow, still some work to do, but that was a great moment for me.