Question on approach to reassembling my R65LS

[Red_Hen]

've bought a R65LS in need of lots of TLC back in February.

I took her apart and had the frame sandblasted & painted, did the POR treatment in the fuel tank, overhauled the engine w/new rings & valve job & general cleaning / painting where the black paint had peeled off and had the transmission serviced (had a broken clip).

I've cleaned all the parts and rebuilt the carbs. Every part from front to back and top to bottom has been cleaned.

I took pics of the wiring harness and was thinking of first putting the frame back together, center stand, swing arm and front, rear wheels on. Realize I'll have to take off the swing arm after to put the transmission back in. I do have a m/c lift.

I also have a Clymer full shop manual. I want to start putting her back together again - any good strategies for getting started?

Not in a big hurry. Hoping to have her running by Spring.

Thanks,

Ken in MN

[Bob_Roller]

I'll quote the maintenance manual for my first car, a '76 Fiat X1/9, on reassembling the engine, 'reverse disassembly procedure'.

[Mike V]

Ken,

I'll give you my procedure since I'm nearing the end of this process at the moment. I'll just let you know what worked for me;
1.) Steering head and swing arm bearings.
2.) Swingarm.
3.) Front and rear suspension.
4.) Wheel Bearings.
5.) Complete brake work front and rear.
6.) Instruments and signals.
7.) Electrical.
8.) Misc. Body work and assembly.
9.) Cables.
10.) Carbs.
11.) Engine/Clutch/Transmission/Exhaust.

There's always some variations obviously and some foresight is always helpful. You'll find yourself in a corner from time to time but if you take your time and think ahead methodically you can make progress and enjoy yorself at the same time. The hardest part for me is knowing when to quit on a daily basis (normally weekends or evenings). If you're not in a hurry give yourself a practical itinerary and schedule while reserving time for photo documentation for each session. It's nice to look back at a photo album of what you've done. And don't forget to try and plan ahead for parts ordering. Don't start a project unless you have all the needed parts in hand. Hope that helps. Enjoy yourself, take care of the details...that's what will give you satisfaction in the end and secure a safe machine. Visit this forum often - it has made my project much more enjoyable with the help of many from parts to in depth experience. Just knowing there's someone out there willing to help is a comfort. This forum has been a life saver for me along with other reference materials. Take the time to do your research and study and don't ever be afraid to ask if you're not sure. Most of all...have fun!    

[Red_Hen]

Thanks very much, Mike - your approach helps a lot!
I need to replace my rear shocks - any suggestions?
Also, do I need to buy a rebuild kit for my Brembos?  This bike sat out in a couple MN winters - I am planning on new stainless brake lines.

Ken

[Mike V]

Ken,

Depends on what you're looking for regarding shocks. Personally, I just purchased a set of Bob's replica shocks for my /7 and I'm very happy with them. They are very adequate at a resonable price. A lot depends on your riding style, bike setup and personal preference. I'm sure you can get plenty of recommendations here from the guys. My 650 still has the OEM shocks at the moment - I'll decide if they need replacing after I get some miles on it.

Might be a good time for the brakes, especially if the calipers are already off the bike. I'm pretty particular about brakes and the replacement kits are resonably affordable. If the bike has set out in the elements for a long time it's possible it's drawn in some moisture. How was the system operating before dissasembly? It's not a tough job, just be thorough, take your time and cleanliness is key. Here's a link to my brake job. Even though mine are ATE's, the Brembos should be very similar...
http://s428.photobucket.com/albums/qq8/gruntyman66/81%20R650%20Restoration/Front%20Brakes%205-09/?albumview=grid
Keep us in the loop!

[bruce_launceston]

Hi Ken, I bought a pair of gas shocks that work very well for my LS. They are YSS RE302-330's. Made in Thailand of all places. Got them from Y.S.S. (Australia) Co. Ltd for $450 AUD. Available in black painted body with black springs and alloy ends.

I have never touched my Brembo calipers but have rebuilt the master cylinder 3 times, with a light hone and new piston kit. I bought my braided s.s. lines from HEL Performance Australia, they sell a kit for R65LS's for $220 AUD. You discard all the lower brackets and brake pipes as well as the hoses and I swapped the hoses and bleed valves over so that the hoses didn't rub on the front guard, all pretty neat.

I have photos in the gallery that show the detail if you are interested.

The brakes were impossible to bleed with the new dry hoses, nothing I tried worked untill I bought a vacuum brake bleeder that attaches to my air compressor and bled them in minutes.

Cheers Bruce