Fork seals replaced.
Had the 18thooth 530 sprocket machined down to 520.
Sprocket swapped. 1mm, .039" clearance to the clutch rod! Test Drive, not going insane yet. No issues.
Got about 300 RPM improvement at 70MPH. Now it is now 4500rpm at 70. I like this gearing. I might be able to keep up with commuter traffic now.
Vibes: I bought the big rubber grips and installed them (Grand Tourismo grips from above). Had to cut off the ends for the clip-ons. There is still considerable vibration. But - for what they are, they work really well. Cut the total vibes in about half. The size will take a little getting used to.
After the last ride, I checked oil and it was a little low. I had topped it off with a convenient, random oil (hind sight, I think it was a synthetic). Figuring that I'm still going to be changing oil within 50 - 100 miles, who cares... Clutch slip.
I also noticed the clutch throw at my handle seamed to go almost full extension before final clutch completely engaged.
Response:
Adjusted the clutch rod.
Rod was 306mm, now 305.43mm = .57mm shorter. (Was shooting for .5mm / .020".) In inch: 12.047", now 12.025" = .022" shorter.
Oil change.
Using Motul 4T 4-stroke motor oil. 3000, 20-50W
JASO MA Mineral oil. Learned alot about modern oils.
No more clutch slip. Think I will stick with MA or MA1.
While I have the side case off, changing sprocket and clutch rod length, oil drained... Why not remove the Starter cover and try to stop a minor leak. I'm not 100% sure where the oil is coming from, but suspect it is this starter plate - behind the counter sprocket. Thought I had a spare gasket, but no. So, I was very careful and able to recover the gasket, then use "form a gasket" on both sides of that.
Should be good to go, right?
Unfortunately, it still leaks oil. It could be from some other location. However, I noticed that one of the six bolts, would not safely hit 7 in-lbs. It got up to about 6 (soft, doesn't feel like it is getting tighter, like the others...) and the others were safely at 7 (felt strong, like they could take more). So, thought I would try it.
While disassembling the plate, it did seem to have oil between the gasket and the cover, in that general area. That one screw could be the root cause...
Hmmm... Is that a blind screw hole (bottom left screw)? I might need a bottoming top, then add helicoil... TBD...
If it isn't from that area... thoughts? Suggestions for finding the leak location?
Now sitting at exactly 100miles on the odometer.