I figured out the clutch issue. Jam nut backed off, got the adjuster out of whack and broke the case when I pulled in the lever. Got a new cover coming in this week (so they say), got some new springs too.
figured it was time to address some other issues while I am down. I spent my time getting it road worthy, skipping the less important things.
my speedo quit on me at some point, pulled off the cable at the wheel and the steel cable inside came out in three pieces. No explanation needed there. got that on order too.
my front brake light switch was never there. tried to find another switch to wire up and decided I would replace the whole lever/master cylinder instead. got me a brake lever/master cylinder assembly off a 660 raptor, complete with switch.
figure I'll describe what I have done up to this point, as I jumped on here a bit later in my build.
1st, I removed the Windjammer fairing and highway bars. If I were 15-20 years older, maybe I would keep it, but for now its in the shed until I decide what to do with it.
Then I bought new rubbers for it, went with a dual sport style because I am out in the sticks and live on dirt roads, but I do commute 20 miles on a county road to work. they are considered 20/80 (20 percent dirt/80 percent street)
I removed the shocks and put on some struts. I toyed with hardtailing it and I still might down the road, but my advantage with struts is if I decide to make a ride back east (or west for that matter) I can swap in a set of shocks for comfort.
I also removed the old seat (which fit perfectly but had "SUZUKI" printed on the rear) and toyed with several seat options. I fabbed up a bolt on solo springer seat. again another advantage to bolt on instead of the standard weld ons you find is that if I should decide to take a long ride with the missus I can unbolt what I have and put on the old one.
I ended up lowering the bike to 9 inches from swingarm bolt to frame bolt (in regards to shock mount bolts). I had to remove the center stand in doing so. wouldn't work with the height.
in removing the windjammer, I lost my headlight. Got a standard 7 inch round mounted with some 'cafe' style fork brackets, added a rock guard and away we went.
I rebuilt the carbs, found a stripped out mixture screw that was super fun to remove with a "not-so"-easy out. added some pod filters because the airbox was cracked and I wasn't spending the money for a new one.
before my big clutch explosion, I put in a set of new fiber plates. fought with that forever because the guy who had it before me had two extra plates in there, a fiber plate and a plate that looked like a fiber but had no pads.
I painted the wheels, tank and fenders and a few other odds and ends like covers and what not. added a sissy bar from a 71 cb350. although there is no seat for a sissy, I put sissy bars on so I can strap a pack to it. also hangs my medic bag converted to a tool bag so I can carry more tools (spare fuel hose, small bicycle pump, tube patches, fix-a-flat can, zip ties, rags, etc.)
I got rid of the big old round mirror and added a pair of cheap low profile mirrors ( I am not pleased with their performance)
I also scrapped the original taillight and blinkers. added an LED dual setup. very pleased with these. running lights, brake, turn signals and LP light.
I cut the bells off of the mufflers and added some turn-downs. also I wrapped the headers.
On my shakedown run I lost a footpeg. Didn't see that coming, and when I stopped to look for it my chase vehicle said it bounced into the tullies so there was no point searching any longer. put on a set of dirtbike pegs I had laying around and am pleased with them.
Thats about all I think. Other than valve adjustment and points. Still trying to come up with something for the left side cover. the PO didn't give me the side covers and at $100 bucks a set, I think I will stick with the exposed tank on the right and try and cut an old road sign for the left to hide the ugly wiring.
