Gammaboy

No, you need a plug piece.

Like this. Appears I under estimated - they'll do 6000psi. allegedly. https://www.harborfreight.com/grease-gun-with-pistol-grip-66664.html

Axle is same part number as RF900 and SV650 FWIW.

Workshop compressed air - 120psi. Grease guns are good for up to 3500psi. Messy, but don't shoot pistons across the room, don't knock your hearing around and will actually move stuck pistons.

What are rifleman's inserts?

Are the circuit breakers themselves unreliable?

throw the fucking 16" front wheel in the bin.

Spread over the 10 years it's been on the bike, it's like $20 a year. That's low budget.

I'm using a pingle.

Are you locking it down to the stand? Doesn't look like it where the centre bearing supports are. Clamp it down, measure, and then take it out and fix with a tree stump and a BFH (Brass faced Hammer, well, copper actually). wear eye protection!

Yep, small rotor Katana 1000/1100 cover.

1100 cover has a casting that seals off the end of the main gallery across the back of the motor. 750 oiling is different, and 750 cover doesn't have the casting, so 750 cover on 1100 results in all the oil pressure dissappearing into the end cover and straight back to the sump. Can you post another shot of the inside of it but including all of the cover? Also, can you measure the diameter of the register that the stator locates on? My Guess is that that's the small stator Kat cover.

Might be easier to go the other way and match the seat lock to the ignition.

Love it.

Yeah, sorry, that's a load of bollocks. Look up the elastic modulus of Ti vs Steel.

Only place you run into issues is with fucking Marzocchi forks, they use a completely different style of dust wiper to the Jap forks, and a slightly different diameter on the OD of the oil seal... 46mm Paiolis RWU and USD run the same seal pack as 46mm ZX9/SV1000 and all the 46mm dirt bike forks (except, of course, Marzocchi).

Unbolt oil cooler, allow to hang below engine, crank engine over to fill oil cooler, top off. Yes, putting the bike nose down makes them take closer to 4l with a cooler (depends how nose down you are). The shitty stock pickup does make them very critical on being underfilled though - because it picks up from 3/4" above the bottom of the pan, and because the design means it instantly pulls air instead of oil as the oil sloshes around, and because most of them actually leak and pull air at the joint between the pickup and the cases. I highly recommend blanking the stock pickup tubes and cutting a pickup hole on the bottom corner of the pickup, and making a gasket for the thing. (I also modified a GS1000 pickup screen to have a removable screen to make cleaning it easier)

Oh, and need to tidy up the radiator fins. And tap the bleed fitting on the top of the bottom rad.

So, found an oil tank I thought would work (late model Aprilia RS125), but by the time I locate it in a spot that works, and move all the electrics tray bits, it doesn't actually gain me much in terms of what I was looking for packaging wise. So, looks like I'm sticking with the fabricated tank up behind the head stock and messing around with locating the oil solenoids somewhere else. Still haven't finished the clutch cable. Need to get back onto that. Picked up the radiators and thermostat housing from the welders - excellent work and well priced, really happy with it. Still need to sort a bottom radiator support bracket and the y-piece for the outlet side. And hose clips.

Your thinking of the Falcorustico I think. Nuda quite clearly had a dry clutch 750...

It ran and rode, which is pretty cool.

Have now sourced a second set of VJ23 oil solenoids (my set has one barb broken off one solenoid, so does the set I've sourced), after the revelation that bending the steel fingers out of the way lets the top piece with all the barbs come off (care of a guy on the VJ23 group), so I'll make one set with good oem barbs, and one set with repaired barbs. Will contemplate mounting both sets so I can make them field swappable in the event that the solenoid itself dies on the road. Also went and measured up a Tyga RGV250 oil tank - it's 10mm too wide to fit because of the shock location. Time to investigate an RG500 tank (the pipe cutouts may let it clear the mito shock), or a OEM RGV tank... just need to find one of each to borrow (although, just had the thought - can I modify the tyga tank with a heat gun enough to clear? Will check tonight).

It's a pity there's not a 4.5" version of the triumph 675 wheels.

oil pump and clutch cable each half sorted last night.

lol. Yeah, I just need to get my shit together. Currently losing most of my time to renovations at the moment though.