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Winter project #2
- Thread starter bosco659
- Start date
I picked up a headlight bezel ring today and with a bit of tweaking, for ok on the bucket. Found more dings on the bucket that had been hammered out (literally) with what looked like a ball peen hammer
. The ring and bucket need the Bosco rust treatment so into the Evaporust it goes. I noticed the wiring harness was excessively long and wrapped to about 6-8” of the connectors. I think it will be much easier to pack into the headlight shell if I got rid of much of the wrap and split the harness into two branches inside the shell. I think it will improve routing of the wires.
I’ll post pics later.
. The ring and bucket need the Bosco rust treatment so into the Evaporust it goes. I noticed the wiring harness was excessively long and wrapped to about 6-8” of the connectors. I think it will be much easier to pack into the headlight shell if I got rid of much of the wrap and split the harness into two branches inside the shell. I think it will improve routing of the wires. I’ll post pics later.
Wiring harness separation. Cutting through the tape that binds the wire is simple using this roofer’s knife blade. You still need to be careful but the hooked end does a great job. They fit into a retractable razor knife handle (safer) but for this small job I wrapped the end of the blade with electrical tape. I think the two branch harness will be easier to fit into the shell.
Oh dear, looks like I have too. Price has been agreed, next to arrange transport.
No hi-jack intended, @bosco659 though it is of course entirely your fault that I've had my head turned in this way!
Lovely...good on ya!
BRILLIANT!!!
Nice catch, Raymondo the magician scores again!
What a beauty! Looks perfect. I know mine will never be that nice.
I’ll be interested in hearing how easy it is to start. Although I’m getting better at it it’s still a chore.
Congratulations
What year is it Raymond? I just noticed the spoked wheels and drum brakes. I’d rather have spokes. Is that a stock colour?
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As far as I know, its a 1998 '20th Anniversary' model - the SR came out in 1978 and I think this one was manufactured in 1999. I'm guessing the Anniversary model has a special paint job and might have been fitted with different wheels n brakes n stuff? The bike has an oil feed to the exhaust rocker shaft - don't know if that was model evolution or a PO mod? A sensible one. Don't know anything about that front brake, but all the SRs I've seen had a disc. Apparently this bike was first sold in Germany and came to Britain in about 2013.
Been in touch with a bike transport company - they haven't advised when they can shift it yet.
Been in touch with a bike transport company - they haven't advised when they can shift it yet.
I’m no expert but understand the front oiler shaft mod was a popular thing to do. Maybe not so much for stock use but for performance applications. Your bike would be a one of a kind in this area.
I’ll be looking forward to your future updates! 
Sparkyduc
XS650 Addict
I had a 1978 SR500 I bought new and in very short time it was like second nature to start it, hot or cold. I sold it in 2006 because of some knee issues, I’ve regretted it ever sinceWhat a beauty! Looks perfect. I know mine will never be that nice.
I’ll be interested in hearing how easy it is to start. Although I’m getting better at it it’s still a chore.
Congratulations
I’m guessing I won’t be posting any start up stories for a week or so. While getting ready to start the beast today, an ill positioned side stand had the bike go over on top of me in the driveway. The bike escaped without damage. It took me a few hours to rid myself of a sore right hip / lower back and it seems to be back to my ”normal” state now. My right knee is however very sore. It’s odd because my left leg took the weight of the bike, but it’s my right knee that’s boogered right now. I must have twisted it when the bike fell. Hopefully a couple days of rest wil fix it back up. Times like this remind me to go a bit slower and be more careful.
Btw, although the bike only weighs north of several hundred pounds, it’s still a chore to pick it up when it’s laying on its side. Fortunately the Moto Guzzi wasn’t right beside it when it went “timber”! If the MG fell on me, I’d probably still be laying there.
Holy Cow! 
Glad you didn’t get hurt worse! You’ve been keeping a very fast pace on this and your other bike. Hope your knee feels better soon!
Glad you didn’t get hurt worse! You’ve been keeping a very fast pace on this and your other bike. Hope your knee feels better soon!
Better now. Ready for a POR15 treatment. Not much else done but I did pick up another gas tank that I may use to replace the dented one.
The bike was missing the left control for lights, signals, horn. The one supplied had a broken wire inside. I bought one from a local fellow that wasn’t in as good of condition as my busted one so I swapped the innards. Turns out it had dirty contacts so apart it came several times until I got a good connection. I’ll try to install it this afternoon although my right knee still has a bad wobble.
Slowly coming back together. The rats nest of wires fits into the newly treated headlight bucket. All gauge bulbs replaced with leds. Might be a bit too bright but I do limited night time riding. Rock hard plastic sheathing removed on the tach side and replaced with a flexible loom. The inside of the chrome tach housing was treated for surface rust.
I was sitting behind the bike and saw ugliness under the tail light. And a new project was born. Yamaha spared no expense with rubber insulators on the light assembly. I’ve gotta put the brakes on working on the bikes. There will nothing left to do this winter!
I was sitting behind the bike and saw ugliness under the tail light. And a new project was born. Yamaha spared no expense with rubber insulators on the light assembly. I’ve gotta put the brakes on working on the bikes. There will nothing left to do this winter!
And treat / recondition those rubber pieces carefully, as most are unobtainium!
Yes will do. Even if available I’m sure they’d be crazy expensive. Looking at the tail light assembly. It looks like the Yamaha parts are more robust than Suzuki. (Comparing tail lights).
