Update of a sort. I'm taking my "MSF" course this weekend. MSF in quotes because it's almost the same thing, but done by the Canada Safety Council. They're closely tied with MSF and many of the materials are shared.
I did my ground school yesterday evening and now it's two days on bikes. 
Bike is being very patient with my having a life and all. I'll pick at it next weekend when I have more time. I wish I had a garage to play in 
EDIT - It's 2deg C and sunny at the moment. So happy I have warm gear. 
akamcfly wrote:
XLR99 wrote:
How long since it's been started?
Also, just noticed the Throttlemeister. Pretty nice throttle lock.
My guess is around 6 months since it last ran. Gas here is ethanol blended, but I don't know if it's any different than US gas. Premium is typically unblended here.
Knowing precious little about throttle locks, I'll take it as a good sign that you approve of this one. It threads backward to what I assumed it would and I thought the throttle cable was gummed or kinked. It moves ok now - left hand thread on the throttle lock. Go figure.
If it was last ridden only 6 mos ago, even ethanol heavy fuels should still be fine. Good luck with it. I remember seeing a few of these as a kid and thinking how futuristic they looked at the time. Not quite as bloated and huge as gold wings got. That would be a fun cruiser.
Finally had time and weather today to pick away at it. I pulled most of the right side panels and put in the battery. I also removed the radio and amp from the right side trunk as any music will be provided by my phone and helmet bluetooth thingy.
I also removed the front seat to remove a wire the DPO put in for who knows what. It went to the front and tied into... I'll have to pull some more plastic to fully trace it. It was near the battery but not actually tied in to anything.
Of the panels I pulled, one was the little one by the front seat that was broken right off and in the trunk. I was able to remove the mounting tabs when the seat was off. I can glue that back together tomorrow. The other badly cracked up panel is the right lower panel by the foot pegs. It's off and will be repaired tomorrow too. It's ABS plastic, so some conditioner and ABS cement is what is normally ised to stick this stuff back together.
I also found a few improvised screws and a missing grommet that will have to be replaced. I managed to nearly strip out the screw under the handlebar clamp cover. That will have to be grooved tomorrow. I want to remove the plastic around the handlebars so I can clean the turn signal switch and troubleshoot the high beam and horn switches. There's an issue there.
It started by the way.
It only took about 15-20 seconds of cranking to get it to fire up. The air filter looks new - I checked it to make sure I didn't suck in any squirrel or mouse nests. Oil will be changed tomorrow. I should have done it today before i fired it up, but it looked like new.
Aaaaaaaaaaand the exhaust doesn't chirp. 
I took a couple pictures that I'll post tomorrow.
Oil is changed and I'm working on panel repair while watching a cheesy movie inside. :)
The horn decided to work again on its own - makes me think it's a corroded terminal at the horn itself. My ZX2 s/r had aftermarket horns that needed an annual cleaning like that.
Still no go on the headlight at all, but everything else lights up. Not that I even looked at the headlight today. I'll check the fuses.
I also topped up the fuel tank with 91 and added some cleaner crap to what was there. It starts happy now (when the kill switch is in the run position)
Just so you know, coworker has one as well. The side mirrors are super duper expensive... like 300 or 400 dollars each.. Enough that he's contemplated buying anotehr bike he saw on craigslist just so he can fix the one broken one he has. (and have spare body parts.)
Yes, ABS plumbing glue will repair panel cracks, but they have to sit a while to fully bond. In other words don't pick at it, you'll only make it worse.
On a few breaks that didn't want to stay together, I reinforced the cracked area with fiberglass drywall tape over the crack itself and sealed that in with 5 minute epoxy. That was after a cleaning with real painters' prep solvent.
It also rained all weekend, which didn't allow more than panel reinforcement and daydreaming. 
Picked at it yesterday for a bit. I degunked the turn signal switch and removed the handlebar riser. The plan for today is to finally replace the windscreen with the original one.
The choke cable sleeve is broken at the threads where it locks to the steering stem. They appear to still be available, so I think I'll just get another one and replace it.
Everywhere I look I find cracks in the panels. At lease I have a method to repair them. I'm going to get a cover on pay day so I can pull some of the larger parts off and not let the weather in. I'm also going to try a fix for the cracks in the seat vinyl. Aquaseal wetsuit/drysuit repair adhesive/sealant. This will hopefully get me through until I replace the bike. I saw some on the diving shop guy's drysuit and it's crazy strong. Fingers crossed and maybe finally a few more pictures. I never seem to think about that while I'm picking at it...
The original windscreen is back on, but the trim panel wouldn't fit back on correctly and the already cracked tab broke off. It's inside curing with a layer of fiber tape and epoxy to back it up. The Aquaseal is on the seat cracks. I'm sure it will work well as it's sticking to the seat like an inappropriate simile.
In reply to akamcfly:
C'est excellent! Ca fait du bien de lire un peu de francais ici!
Nice to see people speack (or write) french here. I can do translation if someone needs :)
Great work on that Pacific. Rare bike. I have honda and yamaha from the 70's, yoour bike seems space age to me :D
In reply to physician:
Merci! Mon Francais est limitee, mais j'aime a parler
I do need to add some more pictures of the progress (he says jokingly). It seems there's a major misalignment in the body panels and I expect I will need to strip the body right off and repair every tab and grommet and see what exactly is distorting everything.
Many panels off and 2 more curing. I pulled off the windshield again as well as the instrument panel canopy, pretend gas tank and the side panels.
The headlight switch is ok and the fuse hasn't blown. I have more digging to do there.
The radio and controls and wiring is totally off of the bike and the old choke cable is off.
Turns out one of the choke pistons was varnished in to its cylinder, causing the cable to be super stiff and the bike not really liking to start from cold. Then I broke the end of the little piston and had to remove the carb(s) assembly to try to fish it out. Soaking it in alcohol freed it up (maybe luck, maybe worth remembering?) but I had nothing to grab it with to pull it out of its port. So I drilled it like one would drill a stuck fastener. The friction of the heat made it bond enough to the bit that I was able to remove it. I ordered another assembly of the piston, spring, plastic nut thingy and macaroni cable thingy. Nothing like buying a few bits of shrapnel for more than the choke cable cost.
But that piston was FROZEN in there.
Tomorrow is wiring the left front turn signal (was poorly repaired before) and chasing that headlight issue.
The Aquaseal is amazing stuff
Happy Canada Day!
Choke is repaired and the carbs are back on. The bike did NOT want to start and I ran down the battery trying to make it go. Seems I flooded it but good. A co-worker popped by on his fancy pants mildly warmed up V-Rod. He suggested I pull the plugs and see. Sure enough they were soaking wet and looking pretty sad. It finally ran about 15mins ago, but I need new plugs.
I fixed the turn signal wiring while the bike dried out and it's all sealed up and reconnected with real live solder! I even took some different coloured shrink wrap and coloured the new wiring to sort of match the diagram.
Having a cold beverage and will be trouble shooting the headlight next. Hopefully it's just the bulb, but the bulb looks fine.
Good that you're making progress! For the choke piston & carbs, try pine-sol if you still need to do some de-varnishing.
XLR99 wrote:
Good that you're making progress! For the choke piston & carbs, try pine-sol if you still need to do some de-varnishing.
Thanks! I even took pictures today. I'll post them in the morning. I'm beat from playing in the sun all day.
Picture Day!
Here's Serge all field stripped to reinstall the carb assembly with new choke bits. She's not being shy, it's just a flat, secure place to work. Not very roomy though. Actually, the airbox is on in that pic but I took it off again later to see if I may have pinched off a vacuum hose.
This is my new colour coded wiring for the left turn signal and running light. It was the closest shrinky tube I had to orange.
The Aquaseal on the seat cracks. I have some on order that comes with a black dye. I'll brush it on over this repair. The stuff is amazingly strong. You can see that the seat is pretty sun baked. I'm going to get some 303 and see if it looks any nicer.
My little battery tender. It works very well. I installed the leads on the battery today and routed them into the cargo hold. After running the battery flat, it needed to be hooked up anyway as there's no possible way to get the alligator clips on the battery when it's on (more like buried inside) the bike.
Apparently, this wing (spoiler alert!) and rear skirt are rare Hondaline add-ons. They're coming off anyway as I may add a top box and/or rack. Plus, the skirt looks a bit silly.
Beddy-bye time for Serge. The cord is going to the tender to get the battery topped off overnight. It should make the battery happy after today's torture session.
THAT IS ALL
Cool! Annnddd off to Amazon in search of this 'Aquaseal' you speak of...
XLR99 wrote:
Cool! Annnddd off to Amazon in search of this 'Aquaseal' you speak of...
McNett Aquaseal. this stuff
New plugs go in today since the old ones are not very nice to look at. More wiring fun today too to see if I can get that headlight to work. I'm going to look for grounds on the frame and clean every one I can find.
I may pull the rest of the front plastic off today to do some repairs. I have one broken off tab for sure and a few cracks. Plus, the lower front fits terribly.
All nekkid and the panels are in the apartment bathtub soaking in dish soap and water. Will be cleaning them after lunch.
YARD SALE!
This is the upper fairing assembly upside down. I'll have to disassemble it to get it cleaned and repaired.
On the bright side, I see no kinks or bends in the under structure, so it was just poorly put together.
On the headlight front, I jumped across the starter interrupt and jumped the headlight switch. I get low beam! :) So the switches and terminals just need a good cleaning. I did clean them last night but maybe the dielectric goop doesn't like to be on there?
I also did change the plugs and the bik was still very "cold blooded" I tried jumping the kill switch, since I was on a roll with the others. It started like it was fuel injected! No drama or extended cranking or partially opening the throttle. Just vroom.
Didn't get high beam though by jumper wiring it. I did have that switch on the bars that I assumed was a high beam flicker added by Serge Sr. I think I'll see if I can trace the plugs with the wiring diagram and see if he meddled with the plug. The wires to the flicker switch were pretty long and went mid way down the left side of the bike. With those wires and that switch unceremoniously yanked from the bike by this clown, I'm thinking I caused the lack of high beam in my haste to return the bike to stock-ish.
Got the high beam with a jumper after my Brother came over for a visit. It helps to check the diagram. The colour codes on the wires are not intuitive.
It all works now and the culprit was the starter switch (EDIT and I reassembled the kill and high low switches WRONG. There's a thread in Sprockets about it) - which has a headlight interrupt built into it. I'll buy a new one as they're still available.
Throughout this week I'll repair the newly cleaned panels and patiently reassemble the front of the bike next weekend. That is, if I have time. I have to start moving stuff to the house too. I don't want to be rushing that so I'll pick at it though the next few weeks
Sooooooo, other than removing the wing and rear skirt (because ugly), it's ready to go for yet another safety inspection. Happy guy 
Great progress! Glad to see it returning to good use.
Ordered a new starter switch - 1 month delivery
Sooooo, I pulled off the switch I have and took it apart again. I popped out the contacts and gave the springs a little stretch and out it back together. I get continuity now without squeezing the switch. It'll do until the new one comes in.
Sorry for the loooooooooooooong delay, but the bike is done. It's undergone a bit of a transformation since you last saw it, but I'm happy with the result.
