Clutching

I attacked the brake light problem and got it resolved without any major problems. The brake light switch on the front lever was faulty, it looked like it had corroded internally, i swapped it out with another used one I had which workes! The rear brake light switch is activated by the fluid so when I bled the rear brake line and caliper the switch is now working.

Regarding the Clutch problem, I can only recon the issue lies with either the spring plate which houses the ball bearing that the pushrod connects onto or that the plates were stuck together from their 6 year mating?
I drained the gearbox oil and removed the basket to take a look at the plates and they definitely need to be changed . . . the springs are well within the service limit. [should have done this at the rebuild stage]

Toothpaste

... and elbow grease cleaned up the front screen which was badly scuffed all over. the first pic shows the screen with the right hand half "polished" and the left hand side still scuffed. The second image is the finished article. A set of Stainless Steel nuts and bolts replaced the rusted ones to fit it to the fairing.

Refreshed Red

Finding it hard to get this put to bed, its close but there are 2 small things that need to be sorted. [1] both brake switches dont seem to be working. All other electrics apart from the horn are working. [2] the clutch does not seem to be disengaging.

The saddles were in very bad shape, I just couldnt get them cleaned, so I got them recovered instead at a very good budget price,

Smokin'

After a few starts and setting the carb to idle the engine seems to run nicely but because of the strong premix is smoking A LOT ! Here is a 7 minute vid of the 4th startup!

Fluids

. . . Had planned to get the bike started today! Assembled all the fluids needed for the prep work, Gearbox, 2T oil, Coolant and Brake fluid [in case I needed to bring it outside].

Got the Gearbox oil filled and the 2T oil pump bled. Mixed up the coolant and found out the radiator was leaking . . .

Front Brake Caliper

I have had the caliper seal kit and new pads sitting waiting to be put into the front caliper for a few weeks now and finally got to it yesterday.

Like the rear caliper the front was badly corroded so after some sanding, dremeling and a few coats of red paint and some new bling stainless Bolts the caliper turned out nice and fresh.

Re-thread

After a short break from the project I put a few hours in yesterday. After purchasing a thread insert kit I attacked the rear wheel that had 2 stripped bolts in.

Very easy to use and did the trick.

Step 1: drill out the broken M6 threads to M8
Step 2: rethread to M8
Step 3: install M8 to M6 thread insert