tok tokkie

I think the real purpose of the heat shield is to protect the rear brake master cylinder & the brake fluid in there. I would check how hot it gets if you do remove the heat shield. I appreciate that Jet Hot reduces heat radiation. Those Jet Hotted pipes look lovely.

Check out vfr800canuck's nickel plated heat shield. More bling in the same area.

It did not occur to me. It was suggested in one of the replys & I said I thought that would have been better. BLS said negative as that removes parent metal. If I did it again Ii would consider that option very seriously - take a good look at how much parent material would remain. The problem with the weld is getting right in there wheras with a thimble you know precisely what you are going to end up with. I will always have an element of doubt about the weld.

Flapper valve: This is what Honda says in the Gen 5 Workshop Manual under Technical Features page 21-25. They call it the variable Air Intake System: 'OUTLINE The intake area and the intake duct length are changed according to the engine revolution speed by opening/closing the variable intake duct, thereby contributing to upgrade the engine output. From low speeds to medium speeds the intake is controlled by closing the variable intake duct to reduce the intake area thereby realizing high efficiency intake through upgraded inertial effect and pulsation effect of the intake air, and contributing to upgrade the low- and medium-speed output. From medium speeds to high speeds the intake duct is opened to supply large volume of air to the engine, thereby contributing to the high revolution speed and power output of the engine.' Next page shows the schematic of the components and explains that below the threshold rpm the flapper is closed, above it it is open. It is generally believed on this forum that it is simply a noise abatement device. I am under the impression that it is thought that the flapper only closes at the noise measurement rpm range & that it is open below that - different to what Honda say (am I right?). I have removed the flapper & the snorkel but have not got the bike back on the road. I expect to replace the snorkel once I have tried it but possibly cut the inside away. Honda's reference to 'upgraded inertial effect and pulsation effect' is Hermholz. The snorkel is thus the Heremholz duct as that is what is in operation at low speed when the flapper is closed. That would slightly raise the airbox pressure over a very resticted rpm range as Hermholz is to do with wave lengths matching duct lengths.

Two days I suppose for the welding & machining - remember I had to make a jig half way through the job & weld some more. I am in no hurry about this, just take it cool. I am doing a complete service of the bike to get it to a known starting point. When I opened the forks the oil was so filthy that I decided I had better check everything out. Plus I am also customising it to a degree - Frankenviffer fever has another victim.

That is a better solution in my opinion. I have picked up so many ideas from this site. What I have learned is that I should have asked for advice and opinion here before doing anything. Sure, the opinions would have varied from 'get a new frame' to 'blow it up' but I would have chosen your method if I had asked the question & got the reply. This is a fantastic site.

7.6 kg with lower inner race fitted.

I agree. Pity he did not say so in his write-up.