I made a much better cartridge holder using a one inch internal diameter schedule 40 PVC pipe available in any hardware store, heat the end of the pipe on the stove or with a heat gun & while hot press it on the cartridge nut but not too hard, pull the pvc tube and cool it with water. you will...
A big thanks to YZFRiderNY I finally rebuilt my 2004 forks that had 22K on them, the video instructions were spot on & made the job go very smoothly, I chose to use Traxxion rebuilt stock cartridge, single rate springs & spring buffers from Glenn, use of a 7 wt oil as was recommended by Glenn...
I just rebuilt my forks with Traxxion cartridge from Glenn with new single rate springs for my weight & while I am at it I decided to loose those useless stock fork protectors & install rubber boots, I found some pitting on the chrome sliders & since I am a daily rider and kinda sloppy cleaning...
I lowered my 2004 Fz1 with 2012 Fz8 risers from parts shark
#16 HOLDER, HANDLE LOWER MBL2 (3Y6-23442-00-P2) 1 $21.04 , 2 are needed
these are the lower part of the risers, the FZ1 stock uppers & screws will fit.
these risers are half the height of the stock FZ1.
also consider lower...
I did the R6 shock & used different dog bones to keep the height stock but after a few months I feel the spring is becoming softer even with full preload, I am 200lb with gear on.
I will replace that shock with the stock shock revalved with a new spring to match my wt, Glenn does the Traxxion...
I do use a foam earplug + the headphone with this amplifier, 95% wind noise gone plus very clear & comfortable listening volume.
FiiO Rocky E02I Black E02IB E2I B Portable Headphone Amplifier w Control New | eBay
Man, since you are using a modular helmet, try these Philips headphones they will give 100% better sound then the Tork x2, I am so pleased with them I am willing to buy them back from you if you don't like them!, the helmet pushes them against your ears a little & you know what that does to bass...
I made similar headphones using a custom ear plug & a high quality Sony headphones still was not satisfied with the sound/ bass, compared to the over the ear headphone I am using now in a scale 0-10, the earplug headphone was about a 3 while the over the ear headphone is about an 8-9/10
Most helmets have a pocket corresponding to the ears, if you can get a small but high quality headphone, hack it and place the drivers in the helmet ear pocket that should give a good sound, I would also use a foam ear plug with the least db rating & not push it properly in my ears, this cuts...
HID is not any hotter than halogen, the headlight will handle it with no problem, I think you're just over worried. making a vent in the wrong place will introduce dirt in the headlight.