AUTO
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Chapter VII: Reassembly Continued
Update 02/07/24
Pieces that I knew it had that I am using include the fuse box and the mounting bracket for the gauges. There was also a coil, rectifier and side cover that I thought would be good for spares. What I didn't know it had that I am using is a complete oil tank and filler neck (it was in a plastic bag in the photos on eBay so you couldn't see it), and a complete wiring harness that I am saving as a spare (and a reference as I re-wrap mine).
Today I sent the day today taking apart, washing, reassembling and installing the airbox, complete with a new lid courtesy of my parts contact in Hamilton (Thanks Obi-wan!). I also cleaned the K&N filter using K&N's own kit (it's drying right now before I re-oil it). When the bike came to me, only one of the orignal seat pivot pins was there, and the second one was replaced by a bent nail. Instead of trying to locate another orignal pin, today I tried using two large angel clips, and they seem to work. You might just be able to make them out in the photo to the right. When the seat is in the flipped open position, there is some play, but when you flip it closed, it's rock solid with no play at all. If I find that they don't work satisfactorily on the road I can always order a seat hinge pin and clip kit from PGM.
The left clip-on actually makes contact with the tank at full lock, something that I don't recall it doing before I took the bike apart. I will have to somehow add a little bit of meat to the steering stop for that side to avoid dinging the tank, especially once the tank has a new paint job. Note the tops of the fork legs sticking out 2.25" from the triple clamps. 2.25" is the difference in length between the RZ350 forks and the stock RD400F forks, so I have to run them that distance up in the triple clamps to retain a semblance of the stock geometry. However, I am going to have to check to make sure that the fender does not contact the lower triple clamp at full travel before riding with this setup.
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Received a box of RD goodies in the mail the other day. I saw this lot of Daytona parts on eBay, and noticed that I could use a few of the parts that I could see in the aution pictures, so I bid on it and won. When it arrived I found that it had even more parts that I could use than I thought it had.
So I spent some time the other day cleaning the oil tank and filler neck, and installing them. I am acutally using my original oil tank but with the filler neck, mounting hardware and rubber grommets from the eBay oil tank. I also now have a spare oil level sensor/sending unit that came with the tank, and the spare tank itself.
I also spent part of today mounting the clip-ons and headlight bucket, and test-fitting the levers and switchgear. The clip-ons I am using are the Tomasellis that came with the bike, although I may invest in a set of new ones at a later date. One is actually slightly bent, but they are definitely useable for now.