Frame, Tank and Seat

• 1). Inspect the motorcycle frame for structural defects, such as a cracked weld or rusted sections. Repair the frame by welding or brazing. Sand the frame, fenders, side covers and chain guard and apply two coats of epoxy primer. Repaint the parts with two coats of the factory color and a clear coat.
  
  
• 2). Remove the rubber knee pads and chrome logo trim from each side of the gas tank if repainting is necessary. Recondition the inside of the gas tank using a gas tank sealer before repainting. Disassemble and service the fuel petcock.
  
  
• 3). Send the rider's seat out for reupholstering. Provide the upholstery shop with two-tone vinyl covering in the stock colors.
  
  

Wheels, Tires and Brakes

• 1). Service the wheel hubs and axles and replace the bearings if necessary. Attempt to restore the chrome finish on the wheels and spokes using a mild pumice cleaner and chrome polish.
  
  
• 2). Select the front tire and rear tire that are compatible with the stock wheels. Mount new factory TR tires or aftermarket tires with inner tubes on the wheels.
  
  
• 3). Refer to Section F in the workshop manual for drum brake information. Resurface the drums and install new brake pads if necessary. Otherwise, disassemble and clean the drums and pads with fine sandpaper.
  
  
• 4). Assemble the wheels and drum brakes and mount the wheels on the motorcycle frame. Elevate the frame on a repair stand.
  
  

Accessories and Assembly

• 1). Compile any replacement accessories, such as the exhaust pipes and mufflers, hand levers, hand grips, lights and foot peg covers. Include a new drive chain, or recondition and lubricate the existing chain.
  
  
• 2). Mount the engine onto the frame. Refer to the appropriate sections in the workshop manual for installing and connecting the ignition coil, ignition wires, battery and battery cables.
  
  
• 3). Install the carburetors and air filters and attach the fuel lines. Connect the throttle cables to the throttle grip. Install and connect the new clutch cable and brake cables at the hand levers.
  
  
• 4). Install the drive chain and the chain guard. Connect the rear brake arm. Mount the fenders and lights and connect the light wiring. Mount the gas tank and attach the fuel line to the petcock. Attach the seat on the motorcycle.