3. The Bodywork, 5. The Rebuild »

So, its been a while in updating the site and the project status, but finally I can get on and explain what the latest is.

After about 10 weeks of the bike being in the spray shop (yes it took about 6 weeks longer than promised) I finally have it back all painted and shiney – now let the fun begin! Having realised that the postage stamp size room I have to work in just wasnt going to be feasable to put the bike back together I have managed to comendere a friends garage. (cheers max)

so with the main body sitting there, I have begun the process of rebuilding, concentrating first on the front end column and controls. It all went together suprisingly easy (maybe too easy?) but within an evening it was starting to look like a bike.

One of the trickier parts was feeding the wiring loom through the various guide tubes and channels to get it from the back to the front, with very little room to get your hand into the appropriate places. A few lengths of the old cables as a guide soon did the trick, but not without a lot of fiddling and taping. Feeding the new cables through was easy enough and so it was just a case of connecting up the headstock and feeding them through the twist grip assemblies.

I was pretty please with the work done, having spent a few hours feeding the wires and cables through, attaching them to the controls, all was looking good. until I realised I had not installed the steering lock, thinking I could insert it through the hole from the outside. I was wrong.

it soon dawned on me that I had to undo all of my hard work to extract the entire front column from the bike to be able to feed the lock up from the inside. eek! An hour later and I had done exactly that, practice makes perfect and it turns out you can do some things quicker the second time round.

The similar thing happened with the installation of the tank, realising I had to take it out to install the rear shock….. and now, it looks like its gonna have to come out for the third time to install the retaining clip for the side panier. oh well, I guess you have to go through the pain of this for the first time to realise what it is required in a scooter rebuild.

Other than the engine unit to go in, the main work is almost complete, and then it is a case of installing the trim and various “nice” bits.

Question: Does anyone have a tool to install the aluminium chrome trim around the legshield – I bregrudge spending £40 on a tool that I will use only once in a lifetime