Throttle Pot Adjustment:

"Pull the boot on the throttle pot down, then probe the White/Pink wires terminal with something like a straightened paper clip. Connect the positive lead to the paper clip, and the neg lead to a convenient ground. Turn the ignition to on. You should see 35 mv-to 38mv. If not, loosen the screws that hold the pot, and slowly move the pot until you reach the desired reading."

CO measurement and adjustment procedure:

"It's pretty simple. The engine should have fairly fresh oil in it, and the throttle body synch fairly close. Connect the gas analyser to power and let it warm up for 1/2 hour. While you wait for it, take the bike for a ride to get it warm. Insert the probe as far into the exhaust as it will reach, and wait for the readout to stabilise. It will change a bit constantly. You want a CO of at least 2.5%. I prefer 3.0-3.5. Turn the pot screw in to lean it, and out to richen. When you're satisfied, ride the bike again and re-check."

I placed an order for spark plugs cables with KpartsHolland.

We made a little progress today. The fairing is now all wired and plastics have been cleaned and put into place along with fuel and temperature gauges.


Tomorrow we venture on to preparing and mounting the rear cowling and wiring up brake and tail lights and turn signals.

After that it’s spark plugs, wires, brake fluid, and coolant fluid … etc … then we add the battery and ecu and abs boxes and see if the magic smoke leaks out.

We have turned out attention back to the oil burner. Because we had badly marred the steering stem from my bike, we decided to pull the stem from the spare frame. 

Because we've never done steering bearing races before we decided to practice on the spare frame before attempting it on my frame. To our surprise the correct steering bearing race puller was in my bottom drawer. buffalohad given it to me back in /2007/!
We did successfully pull the race out. It took /MUCH/ more force than expected but we did not damage anything. 
The next time we'll pull the bottom race out as more practice and then move our attention to start reassembly. 
This should be the last thing on the list that we have not done before. Fingers crossed.

Now that buffalo's boat is sorted and sailing school is behind me, as I had promised, we started on the reassembly project. Tim came by and his help was invaluable. 

Trying to remember/figure out how all the wires run was a fiddly and time consuming process that needed to be done very carefully. I /think/ we have it correct but am prepared to go back in and redo it as many times as necessary until it's right.

This project should be restarting soon. It's been far too long that this bike has been in pieces, as I have been saying for far too long.

buffalo, Ethanol resistant fuel pump assembly and upgraded radiator fan have been ordered. 

I plan on turning wrenches on the bike probably starting in the mid-afternoon. It's going to be a late start to the day.

buffalo and I got a fair bit of work done yesterday. We cleaned up the throttle bodies and fuel rail and managed to get everything installed. 

Separately we made some progress on the crankcase breather modification to remove the "cyclonic separator" from the system. (see other project).

There's still some question about routing some of the new tubing but it seems like it's coming together.

We did determine that the steering head bearings are so bad as to be unsafe to ride so the head bearings will need to be done before the bike can be ridden.

I still need to figure out how to adjust the mixture given that I'm going to be mounting the freer flowing Remus exhaust.

I created some sub-projects to track some of the larger tasks requiring their own research. I think I've made some progress on figuring out a way to bypass the cylconic separator with an external oil vapor tank that looks like it may be the best solution.

We got some work done today. There are still a number of unknowns that I need to figure out:

- the crankcase PCV modification.
- how to replace the steering head bearings
- how to correctly adjust the mixture for the Remus exhaust and balance the throttle bodies.

The rest "should" be relatively straight forward.

I've uploaded some initial photos of the various disassembly phases. It helps to wrap my head around what needs to be done to get it back together again.