I've just got to say that I am blown away with the time and effort that the folks on this forum put into helping those of us that are further down the learning curve. Kawi Wawi's chain removal/installation thread that is going on right now is just the latest example of a long string of incredible information that is being made available.

This weekend, I completed all of the free/cheap mods plus a few others that cost some bucks (Muzzy installation, Moose handguards/screens, folding mirrors). There is no way, not in a million years, that I would have attempted half of that stuff without the detailed instructions and encouragement on this board. Unlike many of you on this board, I don't have a long history of working on motorcycles or cars. I started doing a lot of the work on my Ford F150 a few years ago, but before that, I had never turned a single wrench on vehicle except to change a tire. In fact, it was an F150 forum that got me over the hump with my truck as well. I don't want to get all weapy or anything, but I do want to express my appreciation to all of you that take the time to share your knowledge.

For anyone that is interested, here are the things that I did, along with a note or two on some of them for lessons learned, etc.

1. Moose handguards - Well, new handlebars were not originally on my list of planned mods. The fact that they are #2 on this list shows you that the Moose guards did not go on as smoothly as I had hoped. The fault was mine, though. I got a little off center when drilling out the plug on the throttle side of the stock handlebars. I now realize that I did not have to drill them at all, but at the time I thought I needed to. Even then, I still haven't figured out how I got so far off center, but I did. Luckily I did not damage the throttle tube itself, just the handlebar tube. To anyone that hasn't done it yet, I recommend taking the advice of MaverickAus and punching the plugs out with a hammer & a small socket.
2. New handlebar installation - Easy to do, just wish I hadn't had to do it. I got black MSR Dominator with a cross bar. The seem to be pretty good bars at first impression. The wall thickness is significantly greater than the stock bars.
3. Folding mirror replacement - Extremely easy to do, but a waste of time and $. I realized after purchasing the mirrors that another poster had a bad experience with the same make and model of mirror. They ended up going back to stock, as did I. I have since found a differently style of folding mirror that GravyTrain and some other have. I will be getting a set of those soon.
4. Carb rejet (main & needle) - About what I was expecting since I had read about a million posts here and on Advrider about how to do it. The link to the step-by-step carb removal procedure on the HMF website proved invaluable to me. I strongly recommend having a printout of this post handy before beginning the work.
5. Crankcase breather mod - Easier than expected. I wish I had a torch so I could use Iowaguy's hot drill bit idea. Instead, I just used steady pressure on the back of the bit with one hand while I turned the bit with a set of regular pliers. Most folks seem to use vicegrips, but I found it easier to turn, release, grab and turn over and over again. I am assuming the vickgrip folks would turn, pull back, reposition the bit and turn again. Not sure about that, but my way worked for me pretty well. I started with a fairly small bit and went up in diameter up to 7/16". I would have gone to 1/2" but I broke my 1/2" bit drilling out my stock handlebars. [:@]
6. Smog stuff removed - Really easy. Recommend the carb removal pics to ID what to remove. Looking back, it was pretty self explanatory though.
7. Slide drill - For some reason, I was most nervous about working with the diaghragm/slide. It feels so fragile. Of course it did not help that another poster had a problem with his slide re-install a few days ago. For the record, my diaphragm did grow significantly while I performed the work, but I was working very slowly and had to run upstairs to check the reassemly order of the N1TC needle, holder and spring. It was a really humid evening, so I don't know if that contributed or not. I used the freezer trick that Deej's mechanic had to use. Luckily I did not have to leave it in for hours. I basically left it in for about 20 minutes while I hand drilled the CC breather, and then I was able to get the diaghragm into it's groove. I was very relieved when the bowl seated down so smoothly. For those that have not done this, let me stress, if the bowl does not seat very easily, then the diaphragm edge is is in the way. I had several attempts where I though, "nah, it looked good before I started putting the bowl on. I am sure it is okay. I will just crank down on the screws a little more." Each time my OCD kicked in and I just had to check. I am glad that I did. Each time I found a small edge where the diaphragm had snuck out of its groove a little. Let me say it again, if the diaphragm is in correctly, the bowl will sit right down and wait for you to put all four screws in. If you wonder even a little bit, check it.
8. Muzzy installation - Very easy. Too easy in fact. I kept wondering if I was leaving a step out or something. Man, I fired that puppy up once without the quiet core & spark arrestor. Good grief! It was really loud. Of course it was 3:30am, so I am sure it seemed louder than it really was.
9. Suspension adjustment - I put a link into another thread about a week ago with a reference to a thread on Advrider by Nobiman. A printout of this thread came in very handy when dialing in my suspension. I don't have it quite right yet, but I now realize it is really easy to adjust. I will just keep playing with it.
10. 13T Sprocket Replacement - A little harder than I expected. I did not remove the chain because I did this before Kawi Wawi posted how to remove & reinstall a chain. The next time I will remove the chain. I needed to adjust the chain tension by moving the back wheel a little anyway, so either way worked out okay. Definitely see higher RPMs with the new sprocket, which puts the bike into it's happy 6000-8000rpm range more often.
9. General Stuff[ul][*] Someone somewhere recommended using a head-mounted LED light. I 2nd that suggestion. It really helped me to see what I was doing. Of course my garage is not the best lit, and it was the middle of the night before I finished up. [][*] I used Bel Ray chain oil spray to oil my chain for the first time. It was easy to use, but it continues to drip on my garage floor 1 day after application. I thought it was going to be one of the no-sling wax sprays. I don't have any experience with competing products, though, so maybe this is just the way it works. My only other bike was a shaft drive bike 15 years ago.
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Again, thank y'all for all of the virtual handholding. I look forward to continue learning from all of you as we all get more experience with this great bike. I might even try to contribute on the easy stuff. I don't let a lack of knowledge get in the way of my opinion. [sm=burnout.gif]

Best regards all,
Chris

PS - I still have a Pelican 1400 and National Cycle windscreen sitting in my garage to install. After I get all of that on, I will post some pics. The way it is right now, the bike still looks pretty much like all of your bikes. I will say that it looks a lot more like Kawi Wawi's than Deej's when it come to cleanliness. [8D]

 

Nice job on all the mods, cwgoff - congratulations and good summary. I think the folding mirrors that several of us have and like are the "Ken Sean" style folding mirror. Google for that and you should find them.

 

Yeah, Brian. I saw those before I purchase the one's I got (MSR). For some reason, I did not like the way the bar runs through the back of the mirror. I was worried about durability. It sounds like most folks are pretty happy with them, though. They are all pretty cheap, so I will go for a new pair soon.

In the mean time, I will just remove my stockers when I go off road.

BTW, at the risk of incurring the wrath of Cowboy6, I doubt that he is the only one that is going to have an eye on the 300cc kit you're about to have left over. I doubt I will be in the running (unfortunately ) 'cause my wife is already onto my little "gas saving, commuter vehicle" scheme. It is hard for me to cost justify a more powerful engine for my 4 mile commute to work. She doesn't care so much for the "other" use of my commuter vehicle where the 300cc would figure in. If anyone can help me build a case for why I NEED 50cc more displacement, then I would like to give Cowboy6 a run for his money (no pun intended). Anyway, even though I won't get to participate, I would recommend that you shop that kit around just a little.

Cowboy6, if you are reading this, I hope I did not just cost you any serious $. Good luck with it. I will be as jealous of you or whoever gets it as I am right now that Brian has it. [sm=Awwww.gif]