gs1000g now starts but still running rough at high revs

[DaveWatts]

I feel like a right idiot, I misread the feeler gauges and mistook inches for mm. I'm going to partially blame the feeler gauges anyway, they had rounded numbers for inches and inaccurate numbers for mm, and I could hardly see the numbers (and no decimal point) anyway. I am going to get a new metric feeler gauge and save the other for in case I get a Harley. Looks like I'll need a whole new set of shims as they are all to tight.

[DaveWatts]

That procedure did the job, the bike was more difficult to push with the clutch pulled in compared to it being in neutral but the gears were not engaged.

I have not read all your earlier posts, so I may have missed something - my apologies.

Have you been able to ride the bike recently, or has it been standing for a long time? This will cause the clutch plates to stick together. Before opening the clutch up, try the following:

Make sure that when you pull in the clutch lever, you can see the release lever above the clutch casing moving. Do not switch the ignition on. Sit on the bike. Select a high gear -- 3rd or higher. Pull in the clutch lever and get a friend or two to push the bike forward and rearward (just a brisk rocking motion should be enough). Repeat until the bike will roll without turning over the engine. You will probably hear a slight "bang" when the clutch plates free up.

If this does not work, you will have to open up the clutch. Keep the plates in the same order and orientation when you remove/replace them.

Good luck!

[DaveWatts]

Just a quick update, I finally set the valve clearances correctly. Bike ticks over well but still running lean at higher revs causing exhaust popping. I think the problem must be with the air filter (or one of the boots), probably some air is escaping so I will try to seal it better, it's a shame those rubber gaskets are unobtainable, maybe just a rubber sheet large enough to cover the side cover would work well?

Cheers

Dave