I got a few hours to work on the '76 the last few days, and accomplished the following:
- Replaced broken tail light lens.
- Replaced missing nut/washers on the righthand chain adjuster.
- Replaced my crappy, rusted-out, old black tailpipe with a less crappy, not so rusted out chrome one that I picked up for $20 at a salvage yard a while back.  I replaced the exhaust "donut", all the heat shield retaining screws, and added fiber washers to each screw (not sure that it'll make a difference).
- Recharged the battery for a few hours, though it might need another hour or two just to top it off again.
- Finally got it started (once I realized my $20 tailpipe had a blockage in it) and took a test drive around the neighborhood.
- Replaced the broken kill switch housing...now I can have two mirrors again if I like.  I may post a writeup of the process in case anyone else might find it useful.

I plan on changing the oil and putting some Rotella conventional in it for starters (the oil probably hasn't been changed since the 90's).  Once I get a replacement clutch cover gasket, I'll open up that side and clean the screen and the centrifugal as well.  Then I'll try the Rotella T6 I see mentioned here and elsewhere.

Still need to change out the tires/tubes/rim straps, but at least I have all the parts for those.

It's good to be able to work on the cycle again!

EDIT: Here are some pics of the exhaust before and after the replacement.

Before (note the lovely fix(es) using tintype and other things I can't identify (JB Weld?)):


Before (there was a nice hole right above the battery cover, not visible in this pic):


Before (not sure how long before this section would rust through either):


After (shined up this area afterwards with crumpled aluminum foil):


After (still shiny after all these years):


After (still rusted out at the end and there's a dent, but a massive improvement over the old one):


The final product after heat shields reinstalled:


Adam
Flathead Valley, MT, USA
1976 CT90 - Shiny Orange
1973 CT70 K3 - Candy Riviera Blue
1970 CT70 HK0 - Candy Blue Green (project)
1979 Z50R - Tahitian Red (project)
1964 CT200 - Scarlet Red (project + extras)
1968 CL175 K0 - Dark Blue (project)
1978 NC50 - Pal Green (project)
1982 & 1983 CT110s - Monza Red (projects + extras)

Last Edited By: adzrules Jul 25 12 8:49 AM. Edited 3 times.