All

Shifter done. Welds look ok, but both the old shifter and the wrench were chrome plated and as usual I couldn't be bothered to really clean the metal up. The fit is really good. And while it looks long, remember that the old shifter was pretty stubby. I took a shot of my KTM peg-to-shifter distance for comparison. Carb got cleaned finally. New OEM style vent lines installed. Got some universal number plate sheets and trimmed out the side plates. Also getting the front number plate squared away and found an oldschool cloth...

Thanks Chuckie. This bike was fairly complete, however it was missing a mudflap. I don't even have great pictures of one, but sort of figured out what it should look like and I know it should be white. I mocked up a template with an old cereal box and drug out the original front fender that came with the bike. I hated to cut this up because it wasnt "that" bad, but a vent on back was broken and I was pretty sure that I would never use it for anything. It had a close enough shape to work with...

I havent torn into the carb yet, but the outside is clean so I mocked up the airbox to see how it was all fitting. The airbox side has a 2.75 inch outlet and the carb has a 2.5 inch inlet. The prior owner had a conglomeration of zippy ties and a janky rubber boot. While at Autozone the other day I noticed this guy sitting on the shelf for $10. Its 3 inch to 2.5 inches, but it was close enough. I just had to trim the front and rear (and use brake cleaner to removed the tacky logo)...

Got the triple clamps cleaned up. The lower was missing a steering stop bolt, but other than a good cleaning, everything looked to be in good shape. I'm reusing the bearings and races. The frame rubbers for the gas tank came from a 96-00 RM parts lot. Sure beats the janky radiator hoses someone was using. Also I have two options for bars...dull or shiny. Both are 7/8 Renthals that friends have donated to my garage over the years. The ones that came on this ATK were bent, cheap steel, so either of these will be an improvement...

And 4 hours later on some of the cheapest equipment that Harbor Freight has to offer, I've got a rotor that can be described as "Not as bad as it could have been." In all honestly I think it turned out pretty good and seems to fit the look of the bike better.

I hate to spend this much time on something that is purely cosmetic, but I really can't stand this solid disc.

Got the engine cleaned up. I decided to touch up the black engine paint afterall. New bearings in the swinger, fighting with the axle nut and making a spacer for the countershaft sprocket. I need to get the A-Trak componets and chain back on before doing much more on the axle. I want to make sure my sprocket alignment is good. Also took another vid:

Took it apart again. Talked to Kelvin at Cycle Shed Racing and found out I had a snap ring in the wrong position. Once I moved it, everything was much happier. Shes all charged up again, no leaks, and ready for action. The dust cap gets torqued to 35-45 ft-lbs btw. Forks will be next. I hope to have them apart this week.

Thinking of cross drilling the rear brake rotor. Basically to just make it look cooler. Also got the badge reattached to the frame. The blue looks pretty cool from the red frame.

You're probably getting sick of my posts: Clever Tool making! I like the screw adjuster / setter you've done with the Pin Spanner. . You do / make what you have to. I, inevitably, make my own suspension tools. I recently (tried) to organize my Suspension tools - I've been doing Suspension since the 70s - and it was stunning to see how many 'specials' I've done. So, Very, Many. Thankfully, nearly all I had the sense to label. Some, well, WTH were they for??????...... I guess I'll never know. For anyone else being confronted by a tight threaded seal...

Started working on the number plates. The fossilized decals protected the surface so they will just needed superficial sanding. Here is one of them after a little razor blading to clean up the scuffs and 800 grit. Ill post some finish sanding and polishing later

I really liked the ergonomics on my ATKs. They just fit me well. Here's my '89 406.

I personally think the red framed bike looks great!

Try- red frame, blue seat, white ATK tank graphic with blue outline, and the front fender sticker.

I started tearing the bike down to the frame for powdercoat. I was able to salvage the foil VIN tag with some dental floss. I believe that I've settled on white for the swingarm and frame. Before dropping it with the powdercoat guy, I need to come up with a footpeg solution though, since I want the brackets to be powdercoated white as well. American Dirtbike sells these IMS bolt-on beauties for $200. They are nice, but a little out of the budget so I picked up a set of KTM 450SX pegs for $25 complete with pins...

The freezer pushed this dent out almost all the way. But I'm going to have to weld it up a bit after the pipe split. At least the split gave me an access point to push the dent out further. I got to this point after several hours with a body hammer. For some of the sharp pits that I can't massage out, I will try filling with weld and sanding out. At least this is a natural finish pipe. I can't imagine what I would do with a plated pipe.