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If the RPM's go up when you balance, that's not necessarily the end of the world, you may just need to lower the idle more.

Hmm, there's also the wax motor that keeps the idle high when cold, have you observed it actuating before moving along to set the idle?

It's damn near 100mm. I wasn't aware that any pre-Gen3 FJR's didn't have the idle adjustment screw, I would be concerned that you may have a throttle body rack off a gen3 by accident.

OK, this is good information. I suspect that you have butterflies that aren't well synced up. If a couple of them are open too far, then your RPM will always be too high, and the vacuum measurements/idle screw adjustments will be worthless at idle. There are throttle stops between throttle...

If your final drive gets that hot, you must be riding a BMW.

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That's some nice hardware!

Where are you using this product at such elevated temperatures?

Given that the part number for the CCT has only changed once, a likely purpose of the colored dot is simply a visual indicator that the old CCT is no longer on the bike. If this is the case, any old colored dot will do the job.

Have you started by adjusting #3 to 9.8" Hg? Generally, you are supposed to attempt to get 9.8" Hg and ~1000 RPM idle at the same time.

I'll cover these since George was comprehensive in answering the rest. A fork rebuild generally consists of replacing the slider bushings, fork seals, dust seals, and oil. The valves themselves are generally just flushed out and otherwise left alone. If you're going the extra mile to replace...

This is very good advice!

I still think they just ran out of blue paint.

I see plenty of used ECU's on eBay for $50-200. On the less expensive end of things, spending $75 for an ECU and swapping them out is still a better deal than paying for dealership service. Having both coils fail at the same time is highly unlikely, and you've confirmed that both coils don't...

What kind of balance gauges do you have? Before using them, it's nice to use some "T" fittings and some extra hose to plumb all the gauges to the same vacuum port so that you can check them against each other (you can also use a mighty vac for this purpose). Otherwise, gauge consistency can...

That would be an awfully tempting bike to rebuild as a custom. What do you want for the whole thing?

Awe, thanks Dave. I haven't forgotten about you, I've written Domino's to see if we can get you one of these for pie transport.

Yeah, that transplant is going to be a ton of work! Luckily you have more than adequate space for such an endeavor.

You might only find one or two bikes at Tech Day without risers, you're welcome to sit on mine, and I'm sure there will be a GenII and GenIII that you can sit on also with risers.