Allrighty peeps… This is the giant WTF mutha rebuild of the Dinosaur…I have learned a boat load from this forum and this is compiling a lot of info that already exists…
I wanted to list every mod I have done but also describe why and what the result is so here goes..
The reason I started the rebuild in the first place is I noticed cracks in the frame
the cracks are the same on both sides. I tore the entire bike apart and had the frame gusseted and welded up.
Upon further investigation I found:
The side panels were coming apart and were cracked so I had them welded and rebuilt.
Some of the Riv nuts were spinning so I had them welded in place.
The battery cable at the Anderson connector was frayed and came apartsee the pic…. So i rebuilt them and put in new anderson connectors..
The bearings on the motor lost all of their grease and looked cooked.
The sheathing on the phase wires, mostly the green one was falling apart
Inside the engine the solder flung all over the shop
One small edge of the stator arms was opening (you can see solder all over the place here as well)
There was a factory temp sensor installed in the engine but the wire was doubled back inside the cable run and not connected to anything.
I must have gone past 120c a few times at least...