Long time no post, but I have a bunch of updates!
I finally got my aluminum rearset brackets fabbed up and installed after some tweaking of the mounting hole spacing. There's still a little more adjustment to do, and they have some flex, so they will probably need to be reinforced, but at least I can test the bike a bit.
My local hardware store has metric rod ends and metric threaded rod, so I was able to fab up a new shift linkage using the stock parts from the '89 CBR600 rear sets. It is very satisfying how nicely the bike "chunks" into gear - I'm glad I took the time to go through the internal shift mechanisms to make sure they were working right.
The brake side was pretty straightforward - I had to make a spacer for the CBR929 master cylinder, but the hole spacing was otherwise the same. The master cylinder cost less than a rebuild kit for the old master cylinder shipped which was nice. I had some troubles with the rear caliper till I realized I needed to disassemble it and clean it, which I had apparently not done. It works great now, and I have another couple spares if I have any issues with it in the future. There's a nice set of EBC pads back there now too, so that is pretty much buttoned up.
The tail grab rail, tail light, and "trunk" are back on as well. It seemed like every threaded hole back here had to be cleaned up, and I was missing the 85mm bolts that hold the rail in place, so back to the hardware store with me:
I also got the CB650SC Nighthawk oil cooler installed. I was driving myself nuts trying to get the stock lines to fit until I realized I didn't have to use the stock lines and could just use the end fittings with new lines. Duh. The cooler is mounted pretty high up, but that way it will get clean air between the top of the wheel and the bottom of the headlight.
Also, Hondaman's book arrived, so that is some good reading when it's too cold to work on the bike. I did realize that I should have gone through the head while I had it off and port matched it, but I wanted to get the motor back together. Ah well, next rebuild. At least I did the clutch oiling mods, the rocker arm shaft oiling mods and the 5mm bolt delete mod, which should help longevity.
The wiring harness is reinstalled as well, as is the battery box and some of its electronics. I still need to build a pigtail for the new fuse box and set up the headlight and ignition relays. I'm not sure if the headlight relay will be needed with the LED headlight bulb - it only pulls 24 watts. It's probably best practice anyway in case I switch to another light setup. The ignition relay is good for beefier coils, as long as I don't fry the points, right?
I'm also looking for a place to install the solid state regulator / rectifier so it can get good cooling airflow. Oddly, the rear set bracket might be a good spot for it, if it doesn't hit my foot.
The oil tank is also plumbed, so I decided to fill the bike with oil and see if I could build pressure with the starter motor. I cranked it over a bit, but couldn't get oil to come out the pressure sensor hole. After doing some reading, I realized I did not prime the oil pump when I reinstalled it, oops. Some more research suggested that I pressurize the oil tank with air to help force oil into the pump. I used a rubber bung with a barbed fitting I have around for pulling vacuum and pressurizing stuff and carefully used my air compressor blow gun attachment to put some pressure on the tank. I could hear the oil bubbling and the level went down about an inch or so in the tank, so I tried to crank it over again. Ta da, black gold, Texas tea, all over my painted engine. At least it's new oil.
I reinstalled the oil pressure sensor and hooked my multimeter to it and to ground, and set it to the audible continuity mode. The sensor grounds out when there's no pressure, and goes to high / infinite resistance when there is pressure, so I knew when the multimeter stopped beeping the sensor had enough pressure. I cranked the motor over with the starter again, and what do you know, I had oil pressure. I used Rotella 15w-40 diesel oil with Risoline for the ZDDP, and the level looks good. It took about half a quart more to fill the cooler as well as the main system.
