The restoration

The bike came to me in rough shape and needed pretty much every component cleaning, replacing, adding since many were removed over the years.

It seemed that it had been standing for a long time in the weather since there was water where there shouldn't have been. In the carbs, inlet manifold and frame.

The list of work done and components replaced.

Engine

• New seals and gaskets for the top end including, cylinders, cylinder jug base, head gasket, inlet manifold, rocker cover, exhaust, valve stem oil seals. All parts supplied by 4into1.com
• Valves removed, cleaned  and lapped. Oil seals replaced
• Clutch cleaned and checked wear was within tolerance.
• Cylinder jug and pistons replaced with low mileage model. One set of rings had seized on a piston and scored the bore
• Cam chain tension slipper replaced with NOS model
• Head studs replaced with APE heavy duty versions
• All external bolts replaced with hex-head stainless versions
• Side cover gaskets replaced
• Stripped and painted with engine-specific ceramic paint
• New sprockets, sprocket fixing plate and chain
• New Mac 4 into 1 exhaust

Electrical

• Motogadget M-Unit V2 installed to control all lights, ignition and starting.
• Custom wiring loom built from scratch to work with the above
• New Electrosport combined reg/rec
• New Dynatek electronic ignition
• New coils
• New battery and strap
• CB headlight
• New LED blinkers custom fitted to the headlight bolts
• New LED tail/brake/license plate light
• New Koso combined speedo/tach. Tach electronically triggered by connection to the alternator for needle stability (known glitch for this model is swinging needle when triggered by high tension spark plug lead as per instructions)
• Original electrical panel and 2 plugs preserved for simplicity of connecting engine and reg/rec
• New spark plugs
• New spark plug cables, caps and seals
• New ignition lock
• Motogadget mini switches

Carbs and fuel

• Carbs dismantled completely and sent for vapor blasting by Restocycle
• All new carb components installed from Ultimate carb rebuild kit from 4into1.com. Including new floats, valves, jets, air screws, gaskets and springs
• New inlet manifold gaskets
• New repro rubber intake insulator set since the old ones had hardened beyond being useful
• New fuel lines and tank filter
• New petcock gaskets
• Tank sealed with POR15

Chassis

• Bike stripped completely and frame, swing arm, fork clamps, rims, stands and front fender sent for powder coating
• New seals in rear swing arm
• New spokes and bearings in both wheels. Wheels checked and tuned by MSP cycles in Atlanta
• New Avon Roadrider tires
• New tubes and rim tapes
• New front brake caliper
• New brake pads front and rear
• New front fork tubes
• New internal fork seals and oil
• New fork top-nuts and seals
• New rear remote reservoir shocks
• New Allballs Racing head bearings
• New Emgo street bike handlebars with new clamps and bolts
• All painted parts stripped, modifications to tank made to cover the gap left by using a lower seat. Bondo'd and painted with VW Dove Blue.
• Rear seat, cowling and base plate supplied by Dime City Cycles
• New throttle cables
• New clutch cable
• New brake hose
• New headlight tabs (ears)
• New gas cap, seal and latch
• New brake and clutch levers
• New throttle 
• New handlebar grips
• New mirror

As it was when I bought it

Partially stripped

Carbs before blasting

Carbs after vapor blasting

Custom wiring

New charge controller

Welding up the gap in the tank

Welding in the Dime City Cycles cafe hoop

After powder coating the frame and rims

Lacing up the wheels with stainless spokes

Truing the wheels before sending to MSP cycles in Atlanta for final tightening

Engine back in

Test fitting the tank and cafe seat parts

Wheels after truing and new Avon tires

Test fitting tank, and other parts

Parts in primer

Painted with VW blue