Hello there!!

Good job !!

Adding air to forks almost always results in oil leakage past the seals.

 

Ran it a little more today. Either it's the Sea Foam, or the fuel is evaporating out of the canister (or both). The idle has dropped a bit. I also need to realize that the idle screws are set at factory settings (per the manual). Hopefully in the next few days I'll investigate how to adjust these and that may also help.

I rebuilt both front calipers today and got to the master cylinder before realizing at 9:30PM that I don't have snap-ring pliers. Oh, well, another excuse to go tool shopping.

 

More progress today. Front brake system completely disassembled, cleaned, and reassembled. They work perfect. As I was hoping, the clutch apparently needed to warm up a bit and now works fine. All electrical (rear seat cowl, headlight cowl, signals) back together and functioning fine.

I pulled the smog canister just for kicks but other than a bit of a fuel odor, there was no liquid that I could detect. Anybody have any tips on ditching that thing? Engine is still idling high after warming up and smoking a little bit (seems to be fuel related). Also, though I haven't searched much yet, I need to find the procedure for checking idle mixture. This may solve a lot of my issues.

Down to:

Rear brake rebuild
New battery (still using my DRZ Shorai)
Tires

Getting close.

 

Very cool that after sitting in a garage for 19 years or so there are only a few rubber pieces that need replacement. Thanks to Partzilla I've got four of them so far.

 

Did some plastic repair work today. The inside air vent on the left faring had two posts broken off. Luckily these are on the inside. The fix is rock solid, but as you can see it's not pretty. I have seen videos that show people sanding and painting this stuff and it looks great but I'm not going to bother with the inside. The repair consisted of two nylon spacers and two machine sheet metal screws. The mound at the base is the Q-Bond.

This morning I'm going to attempt to repair the crack in the right faring using this method.

 

Finally rode it in to work today. Ran nice and cool on the freeway but heated up a bit when I exited. I'm hoping a thorough flush and new thermostat will solve that issue. Ordered new fork seals and 15wt oil, really noticed the need for a rebuild today....

 

Man! That is awesome. What a steal at $400. Your neighbor's son-in-law probably would think different about selling at that price now looking like that. Great looking bike too. I really like the colors on it. Enjoy.

 

Hey Gigem, any chance you are a Texas A& Fan?