So I'm dragging this back up from the days when I was actually working on this motorcycle. I got busy working at work, working around the house and basically just working in general on other things besides this. Part of it was just the frustration of things not coming together smoothly and I got my ass full.
So after I got it fired up, it sat up for awhile while I got the petcock leaking under control(I think I did since it has no gas in the tank). The oil injection lines started to leak so I replaced those along with the clips that hold them on the nipples. I had to have the front sprocket turned down to a 520 so that the clutch actuator would not rub anymore so I hit up my friend Don to get it taken care of. That step took awhile as I didn't want to just drop it off to him and run, I waited until I actually had time to visit with him for awhile and catch up on the Kawasaki 750 triple engine that he was putting in his 500. So I get back home and put the sprocket on and bam! It still hits the chain. I had to take the clutch actuator off and remove the dust cover so that I could slide the actuating arm a little further down the geared shaft. Finally I have an operational clutch!
Now I am finding that I can't shift this thing into gear on the stand, maybe it'll slip in when it's running? Are these bikes that stubborn?
I did manage to make a battery box and mount up the gauges in a little tighter. The laundry list is: add a front fender, finish the seat/cowl, get the correct length bolts for the linkage, build some new chambers and add a rear mud guard.
As far as the seat/cowl is concerned, I am leaning towards cutting it down to just a cowl containing the oil tank and doing a fiberglass seat pan. I can't seem to get the metal pan to fit as tight to the frame as I would like and I think that glass would allow me to match the contour on the rear of the tank a little better.
And here are a couple of pictures for proof:
I had to go with a slightly older version of the R6 shifter to get that to work also