I think you will find the rims and tires fine, though in my experience "the next size down" from the 2.15/2.50 rims and slightly smaller tires than you have chosen seems to be the sweet spot. I like the 90/90 18 or 19 on the front and 110/80 18 on the back, though I haven't tried a 2.50 rear rim with the 120 tire on the back. A 120 tire on the 2.15 rim will assemble but it really needs the wider rim. I've got a new 2.50 rim, just haven't got round to trying it. If I recall the 120 tire I tried needed to be trimmed to clear the chain even with the too narrow rim. The larger tires seem to take a bit of sharpness away from the handling with the combos I've used. I really like the Avon tires and have been using them pretty much exclusively since I bought the first set. I think you have to lean on the bike a little on some bumps to appreciate the brace, but it does help noticeably. I'm a big proponent of a brace and a damper. The rotary stock piece is poor but it does work WAY better than nothing if you rebuild it. Even a crappy piston style is a lot better though. I've come to really like a 19" wheel on the front too as it adds a bit of trail and high speed stability and oddly does not seem to slow the steering, though the bikes I have put he bigger front wheel on had other mods so it is not the most objective assessment. Swapping the forks so the worlds heaviest brake caliper is behind the leg and closer to the steering pivot is one of the better things you can do to improve the handling and stability of these bikes and costs nothing. That will put the speedo drive on the other side and so it will spin backwards rendering the speedo useless, but you can fix that by rounding up a hub from a TX500 which had provision for a second disc. That hub is otherwise identical to the 350's, so you just lace it up and put the disc on the opposite side and bolt it all up like it is now.
Very nice tasteful bike you have there. Never heard of anyone drilling their disc with a hand drill before - you're a dedicated man!
Mobius, first off, love the build, pure class!
I think you're right about tire sizes, I almost got the 90/90-18 110/80-18 combo but ended up going with the larger sizes mostly because the front/rear diameter ratio was very close to the factory fitment so was hoping to keep the trail close to factory(I won't lie though, that wider rear tire really appealed to me in the store). To that end I raised the forks in the triple trees to try to make up for the increase in trail due to the taller front tire. In the end though, the increased weight of the new front tire had a larger effect than I expected so all that planning was less effective than I thought. Not that I totally dislike the new handling, its certainly more modern feeling with alot more stability, I just kinda miss the flickability of the factory skinnies. Luckily, my local motorcycle superstore stocks pretty much all the Roadrider sizes at reasonable prices so swapping around should be easy and relatively cheap.
I never thought about swapping the fork legs, great idea and since I've gotten rid of the speedo makes perfect sense for this build. I'm still playing around with fork height next time I make a adjustment I'll swap sides, thanks for the idea!
Those U-shaped forks did not always fit properly and either pushed the forks further apart from each other or pulled them closer together, increasing sticktion.
I"m glad you mentioned that, I thought I was just being anal when I opened up the factory brace quite a bit to just barely touch both forks before assembly, its nice to hear that that additional step may have actually made a difference.
"U" Shaped braces were always marginal. Ones that bridge straight across, not using the stock fork bosses, are much more effective. The brace should not only eliminate flex, but also friction, and with forks friction (especially flexy ones) is everything. I would tend to think that with a good brace and a fair amount of seat time you would be able to tell the difference in a back to back test. I know I can even with the 38mm forks on my RD, but you really have to be riding the crap out of it get there.
I'll definitively revisit the brace idea, have to do some brainstorming to try to make something effective but still attractive.
Anyhow, thanks for all the input guys, really appreciate it. I should have some more pics this weekend as I plan to make a aesthetic change this weekend.
Talk to everyone later, Doug