97 Vmax 500 XT turning into a 700

[jonmalick]

I am fairly new to this site, so bear with me. I bought a 1996 Vmax XT rolling chassis which in turn has the 97 body style, therefore I am calling it a 97'. It was raped of the motor, part of the jack shaft, windshield, & handlebars. I say raped because they even cut the frame over top of the clutches that I am going to have to put back together and brace up. I have then proceeded to purchase a 1997 vmax 700 triple red head with miscellaneous parts from another member on here (thanks Chris). I have purchased some other parts since I bought the chassis. Airbox, secondary, silencer, & coils. Now everything needs a good cleaning.

 

[jonmalick]

Got her cleaned up, installed the wiring harness from the donor sled, replaced the jack shaft, installed coolant & oil tanks, changed the motor mounts, changed coolant lines, & installed the fuel pump.

 

[musselman]

Good to see you saved that sled, I hate to see them all cut up like that. Good luck with the rest of the project

 

[Dmace]

Boy, that's a lot of work! I wonder how much "structural integrity" you lose with that brace broken over the clutch.
Good luck gathering parts!

 

[00sxrjoe]

Not only structural integrity but keeping the brg in line on upper jack shaft after they chopped it up. How bad is the rest of your donor chassis? It looks straight where they chopped the other one.

 

[jonmalick]

Donor chassis is good on that side but I think that I am going to try and straighten things out this weekend and maybe next summer change it out. That is a lot of drilling and riveting to replace that. It goes from one side, down under the sled & back up the other side. It is a U shape piece. I also have the brace for the other side, just don't want to put it in till the motor goes in. An inspection of the motor is in order before I put it in. It is supposed to be a red head, but either the paint is faded or something, because it is an orange color. Lots of work to do yet, but it will be worth it. Kind of satisfying.

 

[super1c]

I think its very cool! Keep it up! Welcome to the site and ask for any help needed. Just make sure you keep up the pic's. Love Pic's. chris

 

[jonmalick]

Thanks, Chris. I was reading up on your tear-down & rebuilding of Elizabeth's viper. That is awesome that she was right there with you most of the time helping. My son is 13 and I think that we are going to tackle something next year for him. My time is consumed with my VMAX project. My daughter is only 7. she will wait. Does anybody know why my red-head is orange? The best I can tell it was not sitting in the sun.

 

[A couple of bucks]

It is supposed to be a red head, but either the paint is faded or something, because it is an orange color.

Kind of appears that the head got hot.

 

[jonmalick]

Red head 700

It has the same coloring even on the underside where there is paint.

 

[jonmalick]

Got some work done on the VMax this weekend. I am not a machinist by far but do not think this turned out too bad. Got the frame straightened out and got some bracing put in. Thinking about some extra bracing on the outside of the frame. Not sure if I will need it. The 700 motor is going to put some torque on the frame, so I am really considering it. Any thoughts? Also, pulled the head off the 700. Cylinder walls look good. Next going to pull the bottom off.

 

[00sxrjoe]

Looks good from what you started with
Did your donor chassis have a coolant leak? Or a stud in the heat exchanger?

 

[jonmalick]

The front heat exchanger is rough looking on the donor chassis, but I dont think that it leaked. It looks to have been hit with a stud or two. It doesnt have the protectors on the front. The left side heat exchanger is missing.

 

[jonmalick]

Can somebody take a pic of how their recoil rope is routed out of the recoil to the console on their red head 700. I am trying to figure out how I am going to modify mine for the 700 motor. Thanks in advance

 

[jonmalick]

Never mind, figured it out the recoil routing.

 

[jonmalick]

While trying to remove my magneto flywheel, I snapped of an allen wrench & rounded another. How do I get these out???? HELP!!!!

 

[super1c]

No help for removing the flywheel. Last time i did that on my pogo 96 eveything came out ok. Just use good tools, PB blaster. Not sure if a little heat might help. But man the project looks great. Nice job for sure! That is going to be a sharp rebuild!

 

[mrviper700]

While trying to remove my magneto flywheel, I snapped of an allen wrench & rounded another. How do I get these out???? HELP!!!!

you need map gas, this will heat those little allen head button bolts and release the loc tite on them. If you stripped the head out already, use a SHARP cold chisel and lay the blade at a sharp angle to the head of the bolt and strike it to loosen the bolt. Youll need to replace the bolts with new but youll be able to remove them and get flywheel off with a good 3 bolt steering wheel/harmonic balancer puller.

 

[00sxrjoe]

I have had to weld nuts on to take out the stripped ones before then replace with new bolts

 

[jonmalick]

OK, got the flywheel off, 1 bolt off the magneto, & 1 off the wire clip. Unbolted the bottom case & the thing seems like it is still attached on the magneto end. What am I doing wrong?