here i go again.. project: 'too late to go back now'

[08rangerdan]

I have a bit of an issue,, maybe one of you can steer me towards the solution before I dig in. I went to go take the bike out for the maiden tonight and it won't go into second??!!

I thought it may be a clutch adjustment but I got all that fairly close to spec.. And re-checked it of course..

Now I'm thinking something on the gear selector within the clutch side wasn't possibly aligned correctly. Or missing.? I do feel the spring resistance on the lever and it bumps down into first promptly without a fuss. Coming back up to neutral involves some more effort than usual. anything above neutral feels like a brick wall. And it won't key in while rolling either..

What could I have missed in there?

[08rangerdan]

I figured it out.. Worst case scenario.. Had to crack open the cover and remove all of the clutch to expose the mechanism involved in the shifter action. I must have knocked the selector shaft and miss aligned the mesh when I was inspecting the clutch last. After I centred it and tinkered for a bit I was getting all my gears again.. All sealed up now.

Another test run tomorrow, hopefully a little more successful..

The area of interest.. Realignment in pic

[08rangerdan]

Well you have done a really nice job on this project but I think it is slightly spoiled by the wrapped headers. Where the collector is covered it makes it look heavy and cumbersome IMHO.

I wonder too about the ability to get the bike certified and insured. I am pretty certain it would not pass without a rear fender and I don't know if the insurer will cover a modified bike.

The insurers are getting harder and harder to deal with in Ontario and it seems to me they are looking for ways to opt out of providing bike insurance. One of the ways is to deny taking on bikes that are modified, especially if those modifications are structural, suspension, braking and or engine related. I ran in to this last year with my FZ and just recently, while checking in to insurance for a CB650 that I am working on now.

In both cases I was asked , "Are there any modifications to the bike at all, suspension, engine, brakes, handlebars...anything?". In addition, I was told I would need to submit a dated photograph of the bike. Three different insures I spoke with stated point blank, "We do not cover modified bikes".

I don't know if you have checked in to this but even if you have obtained coverage, it would be in your best interest to make them aware of your mods and have a signed acceptance from them. I know of one case from last year where a bike was involved in an accident and coverage was annulled when the insurer found out that the bike had....and get this....an after market slip on can. Their reasoning was that it was a modification that increased horsepower and thus performance. I kid you not.

Well, notwithstanding that, I do hope you are able to get it on the road and can enjoy it this season.

cheers.

I never had much of a problem insuring it, well,,,, other then finding companies that insure bikes over 30 years old.. I had no idea only a handful of brokers will insure bikes over
That age. My only practical bet for insuring this bike has been through state farm. And believe it or not, with a clean record they still want over $200 a month for this bike..! I'm currently in the process of attempting to find an antique milage restricted insurer. I'm trying to hit a couple hundred a year instead of a couple thousand to insure my weekend toy, or sadly it won't see much of any street use. I have only been riding bikes on the street for just a handful of years, but I'm really surprised I can't find a break for such an old bike. I would never personally hint to an insurer that i have a modified or especially a 'custom' vehicle. I've had a number of 'special' vehicles too date, and fortunately I haven't had any altercations as of yet. I obviously treat certain vehicles like this a little differently then my daily drivers. But I understand how tough it's getting out there.. Even my lifted truck is becoming a hassle to insure the old fashioned way! I was recently denied coverage due to my truck being lifted through a company who insured the exact truck a year prior.. It's unbelievable how restricted the province is becoming.

[08rangerdan]

Got it finally running around last evening! I forgot or didn't realize how well these motors run! Certainly alot more comforting than the drz400sm. The header wrap loves to smoke and stink for a while.. I think I cleared most of that initial phase out of the way.. I think I scared a few neighbours with the smoke coming off the wrap! I'm going to spend the remainder of the evenings getting the carbs spot on. I noticed it likes to idle a little higher than I would like it too when warmed up. And number 4 exhaust header pipe is a little slower getting up to temperature and I get a little spitting out of that carb until it heats up