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Chaps,
I posted a note a little while ago about making a proper rack and pannier carriers; having now sorteed out all of the fixing issues including the use of the pilion foot rest fixings, I am seeking an idea of how many to get made as this affects the cost.
The design is based on the removal of the existing composite rack and replace this with a tubular one (this can be used on it's own) the panier racks would be supported from the new rack and steadied from the pillion footrest mounts. In addition there will be an anti sway bar at the rear. Suggesting mld steel powdercoated satin black but could get other coulours if there is sufficient demand. I have attached an initial sketch of the proposed rack and you will see that I have not tapered the rear of the rack to give better support/mounting for top case/baggage.
With regards some of the other issues raised, I have thought of the following:
Soft forks - As these fork are not adjustable and it is unlikley that the springs have sagged; I would suggest the addition of some aluminum spacer placed above the prings and under the top caps, suggest that these are done in 12 and 25 mm intervals until the correct stifness is achieved (baring in mind that there will be a limit before the springs reach there limit). The correct oil wirght is important but this affects the rebound more that compression so if you have increased the sring load significantly it would be worth increasing the weight (viscosity) of the fork oil but don't go mad as a little increas makes a big difference and in winter they will be siffer than summer.
Low Bottom End Power - I am afrade that with any engine that has a lager bore than stroke, it is almost a forgone conclustion that it is going to be low on bottom end power but should rev freely. I have found that mine is Ok at low revs but when running above 7K is is a different bike. This is no problem on road but when off road you will need to use the clutch alot (good that it's an oil bath clutch and should be able to take some abuse).
Fuel Sender Light Flashing - I have looked at mine as it flashed but it would appear to be a very basic system and when the float bounces a little in the tank it does not have the sophistication to ignor intermitant signals. I have found that the flashing is a good waring and refuel when comes on permanently and this is pretty close to the 8.5l it should be.