Thanks mainline... my boy loves it and it brings back memories for me too.
Anyway, i finally finished the rebuild today. There are a few small tweaks and adjustments but overall its finished. Yesterday, i got it back together but there was a problem with the tranny. I kinda thought there would be as i knew my shift pawl wasnt lining up perfectly but didnt realize at the time that i could adjust it. After some serious thought and stripping it back down, i discovered the set screw that has a cam on the back but i have never noticed without my reading glasses. Pic of problem below...
And the set screw that is cammed at the back but i never noticed... well, i adjusted the pawl using the cam on the set screw and got it aligned like the pic above.. Here is the set screw showing the cam section. Its only 2mm but makes a huge difference.
And finally, below is a pic as its sits after i took it for a test ride in the park next door. Run it through the gears and it is like butter. Clutch works great and motor is tight but great. Started 4th kick and idled well and has a nice snap and sound. The last things to do is a fix the steering lock as the forks touch the tank, shim the top mounting bolts of the shocks as they bind slightly and then just go around and loctite nuts and bolts, check everything over and give it a good wash. Then it will be ready for running in and more checks.
Cheers,
Alex