Blake, I’ve done steering stems the way the way you’re describing and that works well, but the last couple that I’ve done on Visions  I’ve used the Vision stem. I grind the weld off the bottom of the lower clamp and press out the stem. Then, depending on the triple clamps you’re using, either bore the clamps to fit or make bushings if the holes are too large. Then press the stem in the lower clamp. This way you can use Vision steering head bearings. Of course you end up with a steel steering stem and not a nice aluminum one like your project.

If you want a diffent angle for the fork tubes from the steering stem, drawing what you want and taking the angle you need and hole centers from the drawing saves a lot of math and works very well.

Ron

As Ron McCoy did, I intend to make top and bottom triple clamps.  I hadn't thought far enough ahead to think about using stock indicator lights and fork lock.  More decisions to make.

What are you specifically looking for?   I had both a machined top triple made and modified a TLR1000 triple to bolt to the XZ550 neck (not that difficult with a bit of googling before hand)


The cliffnotes version for a front end swap:

find the ID/OD dimensions of the visions top and lower bearings
find a front end cheap that you want to use (complete is always cheaper).  Look up that particular model's bearing specs (I think I used allballs.  At least i used their bearings)
Cross reference the ID of the front end you want to use with the bearing chart to find an ID of the new triple tree stem and the OD of the vision.   If you can find it.  it's a match!
Now do as much googling as you can to find the rough length of the new triple stem.  Make some educated guess as to specific transitions spots (Where the bearings actually sit/the top nut clamps down).   If you think it's close enough- buy the front end and the bearings  Buy two of the lower bearings! (you'll see why)

Now here is the tricky part.  when you get the new front end, mount the new lower bearing on that fits the vision's neck.
mount the front end into the  neck
You'll see the neck doesn't exactly fit.
Put the new bearing onto the triple tree
take a dial caliper and as BEST AS YOU CAN- meausure the offset you need to make that neck fit perfectly.  measure 50 times, and make a detailed drawing!   Measure, remove, reinstall in an hour and come back and measure again until you are 100% satisfied it will be in the correct place.
NOTE: it is better to be slightly "long" than slightly short.  if the neck is too long you can compensate with washers.  if it's too short you're screwed.

Now have someone cut the neck in the middle and add (or subtract) the exact amount you need to make the neck the correct length.
Reweld the neck back together
install bearings.
Look cool with your new front end.


That's about it.  Look at my pictures from March to May 2016 here as I tried to document what i did:  https://stoddard.smugmug.com/XZ550   

Of course, this method is if you accept the slight difference in trail, etc of the new forks.  I have no clue where i wrote down the measurements for mine, but it really wasn't that much of a difference.  Can't tell you if it rides like crap yet as I have the forks installed but havent finished the bike due to moving (a few times).  Most of my parts are in storage bins in my dad's shed until i find some free time to put it all back together.


Blake

At the TCI there is a Yellow/Black wire.   This grounds the TCI when the tach senses an over rev and kills one cylinder.  I use a small probe and release the wire from the connector block at the TCI.  This way you can always put it back to stock if you want to.

I have had a couple of TCI's fail where it would quit running on one cylinder when it got warm.
If you have access to a spare it's a 5 minute swap for testing.

Steve

That sounds a lot like a failing rev limiter. Have you disconnected yours?