| "To Do" list for Bike#1, the REBUILT 400 |
| Item | Parts | Work Performed | Completion Date |
|---|
| Oil change, et al | Oil, filter | Done at 23157mi | 2006Q4 |
| Valve adjustment | None | Done | 2006Q4 |
| Install missing speedo cable | Found old cable in box | Done | 2006Nov |
| Improve tailpiece mount (at front) | None | Nevermind - Tailpiece removed | 2006Dec |
| Replace grab-rail bolts | Bolts | Nevermind - Grabrail removed | 2006Dec |
| Cosmetic rubber trim strip for tailpiece | Rubber strip | Nevermind - Tailpiece removed | 2006Dec |
| Adjust rear brakelight sensitivity | None | Done | 2006Dec |
| Replace main harness fuse (not box) with blade | Blade holder | Done | 2006Dec |
| License bracket | Bought dual cateye with license holder | Done - bent and mounted | 2007Jan |
| Install case guards | Have guards | Done | 2007Jan |
| Replace rear brake return spring | Find return spring | Done - found, installed | 2007Jan |
| Swap exhaust | Have sporty mufflers, need clamps | Done - Mufflers on, sealed the gap, clamped | 2007Jan |
| Coil mod | Have stuff from partsexpress.com | Done | 2007Mar17 |
| New Coil | Got 5 ohm Dyna coil and red wires from z1enterprises.com | Done | 2007Mar17 |
| Replace fuse box | New blade-style box from Wiringproducts.com | Done | 2007Mar17 |
| Air leak at carb boots | Originally had carb boot gaskets, couldn't get them to stop leaking | Done - removed gaskets and sealed with fuel-proof sealant | 2007May05 |
| Glean gas tank with BB's | Did dryer/BBs, naval jelly, water rinse, hair dryer | Done, looks awesome | 2007May05 |
| Install different tank | Which tank, filters, lines, petcock? | Done | 2007May |
| New front tire | Part# 4362-14, Dunlop F11 300-18 FRONT TT $42.47 from RonAyers.com | Done | 2007May26 |
| Front wheel bearings | Ordered AllBalls bearings | Replaced both bearings and one seal (the small one), re-used other seal - Done | 2007Jun3 |
| Gas cap rubber gasket | Have rubber gasket | Done | 2007Jun3 |
| Fix fork seals | Ordered new seals/boots kit | Done - Installed new seals only, had to drill out one screw, sanded down pitting, put together with blue Threadlok | 2007Jun9 |
| Fork oil level | 170cc's 10w fresh fork oil | Done | 2007Jun9 |
| Superbike bars | Got new bars | Installed bars, relocated turn signals from bars to headlight mounts | 2007Jun26 |
| Change warped front disk | Have other original disk | Done | 2007Jul01 |
| Horn | Use old horn in parts box | Painted, mounted, done. | 2007Jul10 |
| Mount side covers | Rubber pieces from bikebandit.com | Done | 2007Jul12 |
| New rear shocks | Tried KZ750-4 shocks for a while | Installed KZ750B twin shocks from eBay | 2008Jan05 |
| Replace old headlight bulb | Ordered Wagner Lighting H6024 Halogen Headlight Sealed Beam Round Clear from eBay | Done | 2008Jun1 |
| Oil change | Oil, filter | Changed oil, filter, o-rings, and cleaned/inspected oil screen (looked great) and replaced gasket at 23750 mi | 2008Jun8 |
| Investigate shift return spring, clutch, shifting in general | Have new shift fork | Found old shift fork worn. Changed shift fork, re-assembled with home-made gasket at 23750 mi... still phantom neautrals occaisionally but MUCH better! Done! | 2008Jun15 |
| Re-set points | None, just want to try and re-align the points plate | Adjusted points, set timing, Done. | 2008Jun15 |
| Re-balance carbs | None. | Done | 2008Jun16 |
| Re-adjust pilots with colortune | None. | Backed out until orange, turned in just barely until orange flickers gone. Done. | 2008Jun16 |
| Re-adjust pilots withOUT colortune | None. | As I ran more Seafoam through, pilots became rich. Adjusted to around 1 3/4 turns out, and is almost perfect! Done. | 2008Jun22 |
| Stainless front brakeline | Got brakelines and fittings from z1Enterprises.com | Installed, bled, done. | 20080705 |
| Front brake seizing up | None | Took apart, cleaned scummed-up o-rings, bled, done. | 20080711 |
| Fabricate headlight bracket | Piece of galvanized steel | Shaped, bent, drilled, installed, done. | 2008Jul20 |
| Re-adjust clutch cable | None, just follow instructions | Done | 2008Jul25 |
| Replace rocker shaft o-rings, and re-set vavle clearance | Have o-rings from BikeBandit | Changed o-rings, re-set valve clearance, done. | 20080816 |
| Adjust cam chain tensioner | None | Removed tensioner unit, cleaned and replaced gasket, adjusted tensioner to spec, set points gap and timing, done | 20080816 |
| Oil seepage at tach gear/seal | None | Installed 10mm o-ring into tach connection, tightened cable end... Done? | 20080716 |
| Swap sporty mufflers | Already have punched-through sporty mufflers | My theory was that the first set of sporties were too restrictive, swapped out for the punched-through, seems better. Done | 20080831 |
| Winterize | None | Removed battery, tbs 30w oil in cyls, tires to 20lbs, up on blocks, carbs removed, tank drained and swished with MMO., brought in for storage (no oil change) | 20081123 |
| Change/check clutch basket | Might use basket from original engine | x | ? |
| Replace temporary air boots with better hose? | Carb mouth is 49mm (1 15/16 ") Current hoses appear to be 2" and work with tie straps. | x | ? |
| Check/install missing engine case screws | Screws | Still need one short screw | ? |
Pilot screws at 1 and 5/8 turns out 20080828 (finally to spec!!!)