1. The seat is original and in OK condition. However, there looks to be the start of a crack in the vinyl at the seam between the side of the seat and where it meets the top. It's about 2" long and will likely get worse the more I ride it (which is almost everyday). Any suggestions on a vinyl repair kit? There seems to be much out there to choose from.
Once they start to crack it's over. Patch the crack there will just make another pop somewhere else. I battled this for a year. Patch, new crack, patch, new crack, patch, etc., until the whole thing was patched, then it started cracking next to the patches, Replaced the cover and then had time to work on other things.
2. Just ordered a MAC 4 into 1 exhaust system. These seem to be popular with Cafe bikes. Can anyone share thier experience? Sound? Performance?
I describe the Mac sound as "infectious". They are louder than the stock 4 into 4 and sound better as the throttle is twisted farther and farther. This makes the rider grin and the police frown, as the sound also makes the dial needles point the bigger numbers. Personally, I like quiet power for the street. Drawing attention from police officers is not in my best interest. I sold the 550 with the Mac on it. There only so much adrenaline you can make in a lifetime, and I don't want to run out of it too soon.
3. Gas - what is the best octane to use on a bike like this?
Regular, 87 pump rating. It's got 9 to 1 compression ratio stock. Higher octane is good for making oil company stock holders grin.
4. Any suggestions for a "non-mechanic" to improve performance (horsepower)? The 550 is good but I live at 6,200 feet above sea level and combined with the hills around here, every bit helps!
Check your spark plug tips for color of deposits. If it's tuned correctly be happy with what you get. Otherwise, it's a better cam and/or overbore (605 kit), with a freer exhaust and lower inlet restriction. Early 650 carbs are reported to help too. Upping the C/R means upgrading the ignition. How much do you want to spend for more HP?
Be aware, if it makes more power, it won't last as long, because all the stresses and wear increase. Best to hop up a spare engine and swap back and forth as needed.
Cheers,