[ace.cafe]

It's mostly the head temps that can get too hot. The oil temps usually stay under 100 °C.
Anyway, if you already have 100-150 km on it already, and the outside air temps are not too hot, it should be okay for that ride.

[Mr.Mazza]

I think its about 80km on the engine so far (Damned speedo throws my counting off haha) but the forecast is 25ish, coolish night. And I have said it's an easy ride, nothing fast and expect a few breaks if I feel she needs it, everyones happy with that, they are just happy I'm riding.
Anyway to tell the headtemps by feel or smell?
The engines nearly burnt off all the shit it dumped out or all the oil from hands handling it.

[ace.cafe]

I think its about 80km on the engine so far (Damned speedo throws my counting off haha) but the forecast is 25ish, coolish night. And I have said it's an easy ride, nothing fast and expect a few breaks if I feel she needs it, everyones happy with that, they are just happy I'm riding.
Anyway to tell the headtemps by feel or smell?
The engines nearly burnt off all the shit it dumped out or all the oil from hands handling it.

I think you'll be all right for the ride. Just be reasonable with it, and don't push too hard, and it should be fine.You don't need to baby it, because it needs to get the break-in loads, but just try to avoid doing things that you know would heat it up. The metal parts are still not worn-in, and so this creates friction heat. You should be able to tell if it looks like it's getting too hot when you stop for a smoke, and you could give it a half hour or so to cool off if it seems like you could fry an egg on the head.

[Mr.Mazza]

Wow, ditched our plan for the city as the footys grand final was on.
Bike felt ok at 100kmph, didnt stay there too long, after the car show we hit the hills, bike had shitloads of power. Only issue was the breather pipe wasnt tight tonight so a little mess was made, a ziptie fixed that, still made a mess everywhere and left oil drips everywhere we stopped.

[ace.cafe]

Amazing what can be done with the Bullet, isn't it?
Not a weak old plodder anymore!
 

[Mr.Mazza]

Amazing what can be done with the Bullet, isn't it?
Not a weak old plodder anymore!
 

Yeah it is, very spritley now!
Now the rear bracket for the exhaust snapped causing the header pipe to be leaky. Time for the welder and a better bracket design.
And I overfilled it when I changed the oil yesterday....very messy

[Mr.Mazza]

Alright wednesday we hit the grinders and mig, and speedo parts avalible locally.
Now, I currently have a headight issue, basically dull high beam, very dull. I remember last year I had this issue but a dealership fixed it for free when they did something else.
Any simple things to check?
Do those two purple alternator wires matter which way they plug into the bikes purple and purple wires?

[ace.cafe]

No, the AC isn't polarity sensitive, so the purple wires can go either way.
But, there could be bad connections somewhere along the way, so you need to check the circuit out.

And the headlight is typically dim at idle anyway. It should brighten up with some revs.

[Mr.Mazza]

No, the AC isn't polarity sensitive, so the purple wires can go either way.
But, there could be bad connections somewhere along the way, so you need to check the circuit out.

And the headlight is typically dim at idle anyway. It should brighten up with some revs.

Right I'll do some voltage drop tests through the ciruit.
The low beam brightens with revs but high is not so good.

[High On Octane]

Did you install the high and low beam wires backwards on the bulb?

[Mr.Mazza]

We made the exhaust brackets but even with some exhaust sealer the header pipe has a wee leak.
I mighy try some copper shit Ive used before.

[AgentX]

Beer can = exhaust shim!  Thin copper sheeting works to. 

I put some strong exhaust springs between holes in the fins and some tabs welded to the header.  No leaks!

[Mr.Mazza]

Beer can = exhaust shim!  Thin copper sheeting works to. 

I put some strong exhaust springs between holes in the fins and some tabs welded to the header.  No leaks!

Thinking that, but its hard to get the header to pull flush into its seat :/

[ace.cafe]

Thinking that, but its hard to get the header to pull flush into its seat :/

You need to get some bloody great channel-lock pliers and bend that big stiff bracket into a place that forces the header tight into the head. Straight in, nice and flush and tight. Any side gaps can be filled with a wrap of beer can metal cut about 1" wide, and wrapped around the end of the header pipe where it fits into the head. That fills the gap nicely.

Get the header where it needs to be to fit right, and then bend the bracket to where it holds it right.

[Ice]

 The pipe needs to go all the way into the head. 
A soft faced 42 ounce dead blow hammer makes persuading it to to so much easier. 

 The same persuader along with whatever else you find to your liking will be useful for bending the header bracket into alignment after the pipe is in.
 
  VeraChem exhaust paste in the tube is my favorite in this case. If you ever decide to try it, thoroughly clean the  pipe and head joining surfaces, knead the tube well to thoroughly mix the contents and be sure to run the engine for several minutes in order to bake the paste shorty after the pipe is installed.