[Christ]

Another thought - If I have to replace too many parts, I may consider changing to a 12V system after all. I can probably use most of the parts from a Lawn Tractor, like the starter solenoid, etc. I already know the starter can handle 12V, obviously... I jumped it with 12V and it didn't even get warm.

I've thought about it a bit more, and because of the lack of availability of OEM parts for reasonable prices, I'll probably end up modding it a bit.

For instance, the mufflers. I've got a pair from a '96 or so Sportster that are going on it, as soon as I expand/weld the head pipes. I'll probably double-wall the head pipes to keep heat in. I may also run an X or H pipe under the bike to help with low-end torque by scavenging the exhaust pulses together.

I had already planned on doing the lights with LEDs, all except the headlight. Not sure what I'll do with that, yet.

Gonna do a complete tuneup while I'm at it, just to make sure that everything is fresh. Instead of replacing the plugs, I'm just going to take them out, gap/clean them, and reinstall them. Even though they're probably the originals, they've only got 1100 or so miles on them, so they're not worn at all.

Meanwhile, the fate of the parts bike has also been determined... at least the front end of it will be used for my Father's Tri-Sport, I want to see if we can get that thing registered and on the road. It won't be original, but who cares... It's got a Yamaha 4 wheeler front end on it now, and it's an abomination. You can lift/shake the handlebars all over the place. I told him I'd donate whatever parts were necessary to make it mobile again, except my hand controls. We'd have to use the 4 wheeler parts for that. So he'll probably end up w/ the 90CC engine/trans, too.