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#21
12-17-2015, 10:41 PM
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The fit of the rear subframe is off. Looks like they did a bit too much welding on it at once or too much on one side first. It isn't square and needs some massaging to fit into the frame.
The Polisport plastics are close, but there are a few areas that needed trimming to fit. Here, I trimmed the fins down to clear the cross-brace.  I also couldn't keep the front of the airbox attached. I drilled the 4 little tabs and put a nut/bolt through. I'll probably add a dab of silicone to these or replace them with a rivet. In this pic, I have just one of the tabs drilled and secured. 
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#22
12-19-2015, 10:30 AM
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I can't believe I missed this! The kit comes with a new airfilter cage that has a lip inside and keeps the airfilter from rotating. DUH!
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#23
12-19-2015, 05:07 PM
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New hoses from MotoHose arrived today. They are listed as GasGas 2012-2015, but a couple trims and they fit my 2005 just fine. I also added an inline cooler that I picked up last year from Checkpoint Offroad and never got around to installing.
Link to the hoses: http://motohose.com/epages/a63cd3c7-...Products/24-78 
Last edited by RockefellerGG; 12-20-2015 at 06:20 PM.
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#24
12-19-2015, 05:10 PM
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Picked up some new-to-me wheels from Mcnut:
 Triple clamps and forks installed. I added the new hose organizer clip. I may drill and tap a new hole to relocate it. 
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#25
12-20-2015, 12:47 PM
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Found a home for the CDI.
 
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#26
12-20-2015, 12:49 PM
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Added some braided loom to protect the wiring connectors:
 I broke the locating tabs on the right side panel. I've added some JB weld and washers to reinforce them. I'm not so sure it will hold. I'll have to order a new side panel. 
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#27
12-20-2015, 12:56 PM
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#28
12-20-2015, 01:01 PM
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Some learnings:
1. I thought the bolt in the center of the airbox bottom was supposed to line up with the seat mount hole. They aren't supposed to. I needed to keep pushing the airbox toward the rear to make everything line up.  2. The flimsy plastic anchor insert are very flimsy. I'll probably tap the aluminum holes or add a rivet that will be semi permanent. 
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#29
12-20-2015, 10:07 PM
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The rubber tank strap was disintegrated. I made this from a bungee and some bailing wire:
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