'Scarlett' '76 survivor. Wrench, ride, repeat...

[Track T 2411]

Family support is a huge thing and it sounds like Josh has that in spades.

Thanks, his mother and I try our best. The rest of his family are, um, 'fickle,' shall we say...

[Track T 2411]

As the original title says, wrench, ride, repeat... Scarlett developed some seepage from the coolant crossover pipes last fall, and we didn't want to dig into it then and have one of the 'elbow' screws snap off or something and have issues with winter weather. The seepage turned into a full blown mess over the winter, so Josh and I tackled that issue first thing. It all went smoothly, but it certainly is a bear getting those inner o-rings installed without removing the carbs.
We also fixed the exhaust leaks by using the OEM exhaust gaskets for a '78 in conjunction with the Harley mufflers. The mounting brackets are pretty flimsy, so we'll make up some better ones at some point.
When we first got her running, the neutral light was acting up, but that seemed to clear up after a bit of use. However, it's now gotten worse, so we'll have to mess with that as well.
The two biggest issues remaining are the flat spot at roll on from 3 to 4k RPM's and a funky vibration in the steering head at slower speeds, braking, and rough roads. The flat spot is mostly just annoying, so we'll probably address that after I get Layla back on the road. The steering head issue seems to have worsened over the last 1000 miles or so. IIRC, there's different bearing sets for early and late '76's, so I need to figure that out, then 'gitrdun.'

[Track T 2411]

After two seasons of riding, Josh logged almost 4000 miles on Scarlett. Me? Maybe a tenth of that...
Anyhoo, this thread started as a project for Josh and I, and the bike served its purpose. Josh has (mostly) kept his nose clean regarding 'the law,' and undertook his 1100 project with a fairly good idea what it would take to finish. The best part for him is that he now has his own bike to do with as he wants. The best part for me it's that I have sole 'custody' of Scarlett!

So, without further ado, Scarlett 2.0!

Scarlett went into storage last fall running poorly and exhibiting some significant signs of leaking from the front of the engine. Let's just say that I was disappointed in Josh's upkeep. I didn't want to tear into it over the winter with limited space, so now's the time!
As she sits today...

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After giving the bike a quick once-over, I discovered this...

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... so off come the carbs!

[Track T 2411]

The 2.0 plan pretty much consists of a 'deep clean and massage' while also addressing any mechanical/ electrical issues I might discover. I know the steering head bearings need to be replaced, and I need to sort out the neutral light/clutch-to-start issue. It also includes going through the brake system, adding SS lines and drilling the rotors.
I'd love to upgrade the forks and shocks, but I'm on a tight budget (as usual) so that may happen down the line.
I hope to do some cosmetic improvements, as well, mostly polishing. I may paint a few items, depending on how things clean up. I also plan to 'undo' the Sportster mufflers, which was the only real 'mod' we made.

[Track T 2411]

And so it begins...

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The battery box is gonna need some love...

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Unmolested wiring!

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A pile of not-so-shiny shiny parts...

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[Track T 2411]

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Almost there! I forgot to bring the special socket for the top triple tree nut, so it seemed like a good time to stop and clean up.
Just a few things of note... the right side hand controls were replaced at some point, and the po didn't run the wires through the bars. The clutch cable is new, motion pro 02-0011, which is listed for all years of the 1000. It's too long, and poorly routed. The original ignition switch was replaced with an Emgo unit (I think), and the plastic base separated while I was trying to unplug the wiring. I'm not sure if that's salvageable or not.
I've removed all the brake components except for the rear master cylinder. The pin attaching the plunger to the pedal is stuck (and I forgot to bring a hammer, as well, lol). I didn't look too closely at the pads, but overall, everything looks to be in good condition. I'm going to replace the lines, of course (they are original), but I need to decide if I'm keeping the section of hard line in the rear. I'm hoping to be able to just disassemble everything, clean them up, and reuse, but we'll see.

[Whiskerfish]

I think the only time I have ever "Had to" replace the hard line is when i tried to remove it and twisted it. Now-a-days I just flush it out good.

[Track T 2411]

I think the only time I have ever "Had to" replace the hard line is when i tried to remove it and twisted it. Now-a-days I just flush it out good.

I was really careful loosening it, having done many, many auto brake jobs, lol! It looks nearly new. I just haven't looked at replacement lines to see what's available.

[Track T 2411]

I've been slow posting, mostly because I've been chipping away at different stuff as time permits, usually half an hour here and there.

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I've got the brake system all disassembled. Had quite a problem splitting the calipers; thought I might twist off the Allen wrench! Everything looks good. I'm sure everything's had a kit installed in the recent past, so all that's needed is a thorough cleaning, assembly, and installation. The calipers did have some granularity in the fluid, so it was the right time for a go- through.

[Track T 2411]

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Also started in on the carbs. Found that the air cut diaphragm was out of place/ pinched between the halves of the assembly. I'm sure it wasn't working properly, but don't really know if it might have caused my roll-on throttle lag at 3-4000 RPM.

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Got a very nicely repaired set of carb tops from cfairweather. While only one was damaged, the others looked obviously weather checked.

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And, did most all of my parts shopping!

[robin1731]

What did you use to make those carb top buttons look new?

[Track T 2411]

The carb buttons were replaced by cfairweather using his 3D printer made buttons. They are also clear coated. After reading about the many methods of repair/ replacement, I decided that his method seemed the best alternative. Of course, we have no long term durability info, but one has to start somewhere... I'm happy with them so far.

[Track T 2411]

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I've completed the bench assembly of the brake components. All the soft parts were in good condition, as are the pads, so I've reused everything. I thought about stripping and painting everything, but decided to keep the 'patina' theme going. Time to move on to the carbs...

[Track T 2411]

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The original carb towers are pretty corroded, and I'm not sure the jet o-rings were getting a good seal. I lucked out and found a decent carb set from a member here...[attachment=1]20210714_152820.jpg[/attachment]
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Stripped and ready for a good soak! A bit dirty on the outside, but not terribly bad inside!

[pd41044039]

Awesome post. Pictures are great. I swapped a good running Sea-Doo & trailer for my '82 NGW, "Goldie". 40K miles. Boy, did I get the better end of THAT deal!
She had sat for maybe 15+ years because he had gotten a Harley. He only let her go because he sold the house & was moving.
I was able to go on a couple of rides last summer but the carbs (His mechanic had done them but obviously not thoroughly enough) have gotten worse to the point I can hardly get her started. I will be doing the carbs this winter & your pics are very helpful.
I hope you keep posting & I sure hope you & your son can continue to find your way together with the help of Scarlet. My son & I share almost nothing, He lives in Seattle, me in Pensacola, FL.