Tearing down the bike is usually easy – putting it back together is the tough part. The advice here is spot on:
• Pictures and labeled sandwich bags with parts, bolts from each section definitely help.
• Some of the got ya’s – happens to all of us is with the obvious – things like wheel spacers, when tearing them down they all look alike only to later realize that they are not. So get a marker and get to work – lol.
• Follow easy to remember guidelines – like RS and LS (when sitting on the bike). This will help when labeling the wire harness for example – when looking at the rear fender, which cable goes to the left and which goes to the right.
• If you are not changing your wiring – keep clear pictures or diagrams of connector orientation with respect to colored wires (by the way, removing the wires from any connector(s) is a bitch)
• Refer to GASMAN’s Phoenix thread if you ever get lost – it’s truly valuable. (Keep an eye out for the final belt drive, tranny shims and ALIGNMENT all around i.e. engine, tranny, primary, final drives and wheels)
• When reassembling the front/rear fenders I recommend using washers BETWEEN fender and bracket
• Careful when working with brake fluid – under no circumstances do you want it to come in contact with painted pieces.
• Use a “thread repair” tool to chase/clean all the threads on painted/powder coated/Chromed pieces (I prefer that to a tap – if for some reason or the other the threads don’t clean up using the thread repair tool then use a tap)
Just reiterating stuff we know and is common sense, hope it helps. Enjoy the project and good luck.
