Not throwing anything away has paid off over the years. Buying big boxes full of stuff I thought I'd never use, just to get to the one or two bits I needed, has also paid off!The only thing I didn't like so much was the breezy "The [name of part] was bent [broke/missing/stripped], so I just used one I had on the shelf." Don't get me wrong, I'm really impressed with that, but I'm envious of your experience and inventory.
A little of both; I keep the parts book up on the computer screen, then print out one page at a time and check off stuff that's there, or circle stuff I need, as the disassembly, parts washing and measurement stages roll along. Many engine overhaul parts are "no questions asked" replacement such as gaskets, seals and locktab washers.There were some things I wondered about. In post #58 you had a picture of dozens of new parts spread out. To place the order did you make a list of what to buy as you dismantled, or do you have a more-or-less standard checklist of things that are always needed?
Ned wanted an upgraded front brake, and I happened to have one. The knave plate was a purely styling issue.In post 79 you mentioned having the wrong knave plate for the front brake... one that was for a 650. Was that a styling issue or functional. How much difference is there in TLS brake assemblies for 650s and 500s. I'm wondering now if I have one that will suit my bike.
I'm hot sure whether it's do-able or not, I've never researched it.In post 84 you showed the left and right cases with their bushing and bearing. Probably dumb question coming... Is it possible to put in a roller bearing instead of the bushing, as in the 69 design? Maybe with a case modification? If it is possible, would it be recommended?
Nope, he's too big for rearsets. I believe they're available, but haven't looked.Finally, since the project has a cafe flavor, did you or Ned consider rearset footpegs and controls? Are they available?