Banjo450DOHC
Veteran Member
I thought I'd make a thread to record some of the resto modding I am doing on "Aseizja" (I call it this as a joke because it seems like the last guy to work on it must have had "a seizure" halfway through building it and given up). My other stock oem build is called "The Magnum Opus" (for it shall be my masterpiece). The idea with these two builds is that Aseizja is my red headed step child that gets hand-me-downs and inexpensive fixes and creative mods and The Magnum Opus will be done as a perfect build with the more expensive newer parts.
Really this post is concerning Aseizja, which after replacing the right hand handlebar switch the electrical gremlins seem to at last be mostly dealt with. I also did the carb slide test (both carbs seem stellar), replaced the throttle cable, and rerouted the fuel lines in a safer and less resistant manner.
It seems like now the only thing is if I really open up the throttle on it I can get the clutch to slip. I already adjusted the clutch and made sure that the first third of the handle has play like the FSM says to do, I checked the oil and added a bit to top it off and some zinc additive when I first got the bike, but since I have been waiting on the magnetic drain plug to arrive I haven't changed the oil yet so I'm going to do that before I start trying to repair the clutch since I know incorrect oil type can cause slippage and for all I know the previous guy used the wrong stuff.
He definitely had the clutch adjusted way too tight, there was no play in the handlebar lever and when I adjusted using the flathead on the engine side location it was jammed so tightly clockwise I almost couldn't get it loose. My only hope is that because he obviously barely rode this bike at all that the clutch discs didn't get too damaged.
If the clutch still gives me trouble after the oil change and zinc additive is done then I might end up trying swapping out the discs with the old discs from the magnum opus because it's clutch was working fine I'm just replacing the clutch discs and springs while I'm in the engine block for the rebuild work so they should be fine.
Also in regards to the transmission, the shift lever rod has way to much play you can grab the shaft and tug it back and forth about an inch with the shifter lever and cover removed. I pulled the c clip and washer at the base of the shift rod and cleaned it all out and got it installed better than previously and got some of the play out. Then I was able to use a flathead to open the shift lever enough to slide it further down the rod than I otherwise could have (because of the play it runs away from you as you try to put on the lever) and then I did a zip tie to close the small gap still left like the previous guy did.
With that mod I was able to get the bike to where it shifts just fine except for when you're trying to shift it into neutral when you're at a dead stop and the engine is running. I imagine this is probably a broken shifting fork or some such? I thought I'd ask if anyone's dealt with it and how hard it is to solve. If it's too pricey I may just ignore it and keep using it as is. It's not too hard to compensate with the clutch and by shifting into neutral early and coasting to a stop. I'd love to fix it properly if it's not super expensive though.
One mystery item is the lowbeam on the headlight works, but when I attach the white wire for it coming off of the handlebar it stays on continuously no matter what position the headlight switch is on. Mind you this is a brand new handle bar switch box as well. I also did the yellow/white wire mod to make the full stator run continuously, not just full when the headlights are on and half when they are off like I'm lead to believe it runs stock.
Also the rear tire blew out on my test drive last weekend, it's fine I was able to safely pull off the road and get a AAA tow no problem. I think I'm going to swap out both inner tubes and tighten up the spokes and clean up and clear coat the rims on the inside to prevent rust build up.
Also the previous guy removed every last reflector and blinker and painted EVERYTHING on this bike black. Including some electrical connections... I plan on going through with my dremel tool with brass wire brush attachments and polishing off as much of the chrome as I can to make the bike more reflective and pretty. At least the wheels and horn and maybe the engine itself. I think I might even add some yellow LED strips to make sure it's super visible at night since it would be easy and cheap to do.
Eventually I would love to add blinkers back to it (the wiring for them is still there) and reflector circles maybe too. I really prefer to be as visible as possible while riding and it looks great to me anyhow. I already took the old beat up mirrors off of The Magnum Opus and threw them on it which dramatically improved my visibility. Honesty if someone out there has fenders for it I'd even love to throw those back on it someday perhaps too.
I also definitely am not enjoying the low handle bars, I think I'll throw some stock ones back on it eventually or even some riser bars to bring them up a bit from stock height, probably at the same time I do my front forks since I'll need to pull the front wheel and such to remove the modded handlebars off it anyways.
Seen here below “Aseizja” (only cost me $200 on craigslist):
And seen here below is “The Magnum Opus” (even angels weep at her beauteous visage):
Really this post is concerning Aseizja, which after replacing the right hand handlebar switch the electrical gremlins seem to at last be mostly dealt with. I also did the carb slide test (both carbs seem stellar), replaced the throttle cable, and rerouted the fuel lines in a safer and less resistant manner.
It seems like now the only thing is if I really open up the throttle on it I can get the clutch to slip. I already adjusted the clutch and made sure that the first third of the handle has play like the FSM says to do, I checked the oil and added a bit to top it off and some zinc additive when I first got the bike, but since I have been waiting on the magnetic drain plug to arrive I haven't changed the oil yet so I'm going to do that before I start trying to repair the clutch since I know incorrect oil type can cause slippage and for all I know the previous guy used the wrong stuff.
He definitely had the clutch adjusted way too tight, there was no play in the handlebar lever and when I adjusted using the flathead on the engine side location it was jammed so tightly clockwise I almost couldn't get it loose. My only hope is that because he obviously barely rode this bike at all that the clutch discs didn't get too damaged.
If the clutch still gives me trouble after the oil change and zinc additive is done then I might end up trying swapping out the discs with the old discs from the magnum opus because it's clutch was working fine I'm just replacing the clutch discs and springs while I'm in the engine block for the rebuild work so they should be fine.
Also in regards to the transmission, the shift lever rod has way to much play you can grab the shaft and tug it back and forth about an inch with the shifter lever and cover removed. I pulled the c clip and washer at the base of the shift rod and cleaned it all out and got it installed better than previously and got some of the play out. Then I was able to use a flathead to open the shift lever enough to slide it further down the rod than I otherwise could have (because of the play it runs away from you as you try to put on the lever) and then I did a zip tie to close the small gap still left like the previous guy did.
With that mod I was able to get the bike to where it shifts just fine except for when you're trying to shift it into neutral when you're at a dead stop and the engine is running. I imagine this is probably a broken shifting fork or some such? I thought I'd ask if anyone's dealt with it and how hard it is to solve. If it's too pricey I may just ignore it and keep using it as is. It's not too hard to compensate with the clutch and by shifting into neutral early and coasting to a stop. I'd love to fix it properly if it's not super expensive though.
One mystery item is the lowbeam on the headlight works, but when I attach the white wire for it coming off of the handlebar it stays on continuously no matter what position the headlight switch is on. Mind you this is a brand new handle bar switch box as well. I also did the yellow/white wire mod to make the full stator run continuously, not just full when the headlights are on and half when they are off like I'm lead to believe it runs stock.
Also the rear tire blew out on my test drive last weekend, it's fine I was able to safely pull off the road and get a AAA tow no problem. I think I'm going to swap out both inner tubes and tighten up the spokes and clean up and clear coat the rims on the inside to prevent rust build up.
Also the previous guy removed every last reflector and blinker and painted EVERYTHING on this bike black. Including some electrical connections... I plan on going through with my dremel tool with brass wire brush attachments and polishing off as much of the chrome as I can to make the bike more reflective and pretty. At least the wheels and horn and maybe the engine itself. I think I might even add some yellow LED strips to make sure it's super visible at night since it would be easy and cheap to do.
Eventually I would love to add blinkers back to it (the wiring for them is still there) and reflector circles maybe too. I really prefer to be as visible as possible while riding and it looks great to me anyhow. I already took the old beat up mirrors off of The Magnum Opus and threw them on it which dramatically improved my visibility. Honesty if someone out there has fenders for it I'd even love to throw those back on it someday perhaps too.
I also definitely am not enjoying the low handle bars, I think I'll throw some stock ones back on it eventually or even some riser bars to bring them up a bit from stock height, probably at the same time I do my front forks since I'll need to pull the front wheel and such to remove the modded handlebars off it anyways.
Seen here below “Aseizja” (only cost me $200 on craigslist):
And seen here below is “The Magnum Opus” (even angels weep at her beauteous visage):
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