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Thanks everyone for the tips. Had to take a break because of Turkey Day, but plan on getting some fluids tomorrow. My biggest concerns are the shifting from 1st to 2nd and the brakes. I plan on putting MOBIL 1 syn dextron trans fluid into the transmission and adjust the clutch for #1 (got the tip on here), then shoes, pads, fluids for #2. If I can get both of those fixed, she's safe enough to ride.
1. Replaced footboard pads, they were splitting and couldn't cushion the engine vibrations.
2. Changed transmission fluid with Mobile 1 Dexron based on advice from this post. Made a big mess.
3. Changed the primary fluid. Didn't make a big mess, but dropped one of the primary cover screws in my oil pan.
4. Adjusted clutch 3 or 4 times until I got it drivable. 3/4 turn was the right one for that clutch. Clutch point is right in the middle of the pull.
5. Derusted a little bit. Cleaning isn't my favorite thing to do.
Still have the 1st to 2nd shifting issue. Didn't get to test ride much today, will report back on this. It seemed to go away when I had the clutch adjusted a certain way, but the way it is now, I think it's back.
Don't know how many of you guys or gals ran into this but on my 98 the OEM foot master cylinder cover is made out of a real cheap pot metal that actually warped and let moisture in contaminating my rear brake system (happened more than once) which required a complete clean n bleed. You can straighten it and put back on but would like to see an upgrade without buying a complete master cylinder. Any one else run into this?
I don't know what the rear master cylinder looks like on a 98 but if all it needs is a flat surfaced cover then you can probably make a nice one from 1/4" thick aluminum plate.
It'll pretty easy to make with basic tools. Hacksaw, good file that makes smooth cuts to shape the edges and sandpaper or polish it. Drill it for the mounting screws and drill it for the vent to allow the rubber gasket/seal to flex as the master cylinder level changes with use/pad wear. Should be a fun project for you. I doubt 1/4" aluminum plate will ever warp and cause you the grief the stock cover did.
I've made a couple of them for different master cylinders.
Last edited by megawatt; Nov 30, 2014 at 09:32 PM.
No. I found it in the service manual (it wasn't in the index) but it doesn't say where it is. After some internet research, I think I've identified it covered in sand. If it is what I think it is, it's similar to the clutch adjustment screw and lock nut except it's on the outside of the transmission (sticking through) looking in on the left side of the bike.
I need the HD special tool. I assume that keeps me from having to take off the entire primary.
I did the test with the shifter and it seems a little out of whack but I had to test a few times. It's not obvious, but the tolerance is probably pretty low.
I probably need to switch out all the stuff around the shifter spline as well. I got the parts. I think I'm losing energy (with my foot) on the shift because there is vertical play at the spline.
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