So just a brief update on the project.
After stripping back and reinforcing the frame I have painted it and fixed it back to the engine.
The forks which were from an FZ750 Genesis have been serviced. Full strip and clean with new seals. I have used 15w oil to make them a little stiffer. The four pot calipers have also been stripped and services with new seals and pads. I did mix up one of the bottom yoke bolts - it was the one that snapped before it got to the required 47nm torque setting!! (sorted now).
New headstock bearings went in surprisingly easily and came with nice dust seals. Plenty of grease as I don't plan on going in there again anytime soon.
Got new tyres front and rear. Had a long chat with a trike bloke about the front tyre as I wanted something with a flatter profile. As my wheel it 17" the trick it seems it to fit a back tyre. Now I have proved it fits I will be removing the directional arrows or the mot man might not like the way they point!
Filled the engine with oil - will now have to drain the oil and measure it properly because I cannot see anything in the stupid oil level window! The K100 is very particular about oil level.
Stripped the rear axle to check the diff and the condition of the tubes. Not only are these is great nick but the axle turns out to be the fabled B type high ratio - bonus I think. As a couple of the studs holding the diff together have snapped or stripped the threads I removed them all and re-tapped the holes for new metric studs. Gave the whole thing a good clean and hopefully putting it back together this weekend with nice new gear oil.
Fitted the wiring harness and started fixing the 'adapted' sections. For some reason the two 12 pin connectors that go into the clocks had be changed (badly) for 10 pin sockets, with the extra loose wires just connected!
I had a donor harness so I sat there splicing in, total job - cut, strip, twist, solder, cover with heat shrink. All good until I find that the bike has an extra wire..... don't you just love wiring diagrams. My bike has an extra wire at number 8 for the fuel sender. Not a problem, as the donor connector has number 8 blank - do you think I can get the bloody wire to push into the empty socket!!! Socket is empty and the locking plate has been removed but the metal connector just wont push past the tab that is there to stop it pushing back when the pin engages. Might have to drill the tab and then use something else to stop it pushing out when engaged.
So that is where I finished last night at 21:40 hrs.