well, back at it this weekend. i got the exhaust wrap safety wired up, and installed the baffle. i got it at dennis kirk for $20.
i wrapped some MSR exhaust packing around it, and slipped it into the collector. i topped it off with a 9" chrome tip. i don't have a welder, so i just drilled two holes where the mounting screws were on the chrome tip so the screws are into the collector itself. don't think it's going anywhere - seems pretty solid.
i'm still having trouble with the electrical - headlight, neutral indicator light, bright headlight indicator, etc. i also looked it up, and nevada requires turn signals, so i had to dig back into the harness (i was going to run without them). after another 4 hours, i got the headlight, bright indicator, and turn signals working. the neutral indicator is causing me grief, and the tail light is a tricky one.
it's the round glass unit from carpy, and it's really cool. problem is, it has two wires, and the stock harness has three - one for ground, one for power, and one for the brake switch. i didn't have time to monkey with it tonight, but someone on the board suggested hooking the ground to the frame, and the brake switch and running light to the two leads. i'm hopeful that it will work.
i got all of the levers installed, the carbs and airbox on, and a bunch of misc. stuff. this morning i actually got to fire it up! i was elated. the exhaust sounds great - raspy, but not annoying. the fuel/air mixture seems to be off - it's not idling very well, and the throttle response if off. looks like i'll be working on the jetting this next week.
here are some shots with the way it is now, for your viewing pleasure (i used the good camera this time). i'll be honest - i hate the turn signals, and i will probably remove them after i register the bike.