I have "the parts." Waiting for my garage to warm up a bit (Phila: we've had a lot of nights in single digits F recently). Did the rear main seal at 114k and was almost there. This time a new clutch disk is in my pile of new parts with center o-ring, nut etc. A set of parts is also on hand to replace the Rear Drive Pinion seals, using heat etc as posted.
I've read the posts about the sprag clutch, even came across a great set of pics for doing the job.
I've tried the Rislone, CD-2 and Rotella T and tired of bump starting it on and off since about 125K, esp. two up with camping gear or camping on grass, like at Daytona last spring when the rear tire slips too much to start in 2nd gear. It's embarrassing to need some guys to help me push start a motorcycle that I am so proud of and happy with in every other way.
The new parts include the bearings that the alternator enters in case they are worn. I have some idle noises I don't like during the first 10 minutes after starting, raising my idle to 1000 RPM helped these. A new cam chain tensioner and chain rubbing rails did not help. I would describe the noise as "every 5 -20 seconds during a cold motor idle, it sounds like the motor tries to run backwards all of a sudden for a 1/4 of a second." I had thought a loose cam chain might allow this waiting for the tensioner to pump up. It might be related to heavy battery recharging loads related to my upgraded 50 amp alternator.
Some dealer K bike mechanics have spoken with me to help complete the list of "ought to" do this while I'm there stuff. I looked at the 6 rivets a year or two ago, they are fine. It needed a new radiator fan on a trip a couple years ago. It gets Mich PR 3 tires (wide rear rim upgrade) and spline lubes regularly.
Does anyone know about the extra case hole "upgrade" that allows engine oil to wash the varnish build up on the sprag clutch more than the stock '85? Is there a tech bulletin that shows the size of internal hole, the location and the angle?
Followup posts of wide variety are welcome. Thank you ahead of time. Completed Info posted about 6 replies down.