Progress!
I had twins a month ago so I get about 20 min a night to mess around with the bike. But slowly I'm getting things together.
So far I've replaced both handle bars, hi/low switch, horn and button, clutch cable, front break cable, front break pads, speedo cable, air filter, battery, throttle assembly and all light bulbs. Things are running great for the most part. Head light works, speedo works, hi/low indicator and speedo illumination lights both work.
Tail light/break light doesn't work however I am getting around 6.3 volts off the red cable and 6.3 volts off the green cable when pressing the breaks so I know the harness is good. I connected a 6 volt battery directly to the tail light and get nothing so I'm sure the assembly is bad. Ordered a new one tonight.
The only other thing I can't get working is the darn horn. I know the harness is good because I'm getting 6.3 volts off the red harness cable in the head light bucket. I know the horn works as well because I hooked up red to positive on the battery and green to negative and wow is it a loud horn. Made my ears ring. But when hooked up to the bike pressing the button does nothing. Could have I gotten a bad button? Is there a way to test the horn with it plugged into the harness and bypassing the button? I tried grounding the green cable to the frame but still got nothing. But I know there's power to the horn because I do see 6.3 volts off the harness connection.
This weekend's project is replacing the muffler, it's cracked right where it comes off the engine so it smokes me out riding it and is loud.
I also ordered a new rectifier. However I don't really know what is does. Should I replace the original one?
It is interesting that some of the reproduction parts don't quite fit together right. Had to drill out part of the handle bar to get the clutch cable to fit and I had to file down a piece of the throttle assembly to get the stopper to fit.
One last question. How the hell do I get the handle bar grips on? They are ridiculously tight and I can only get them on about 1/4 of the way. Then it's almost impossible to get them off after I give up trying to put them on. I read somewhere about hair spray but that seems a bit odd.