| Projects/Maintenance for Bike #2, the First 750 |
|---|
| Item | Parts | Work Performed | Completion Date |
|---|
| Front..................................................................................... |
| Leaking fork seals | Fork seals (KL15-1411) and Dust covers (44010-032) from z1enterprises.com | Done by Howell Cycle | 2005Q2 |
| Paint spokes | Need paint (Duplicolor Deep Jewel Green or Satin Black) | Done, painted black | 2005Q4 |
| Replace headstock bearings | I have the tapered bearings | Done | 2005Q4 |
| Install braided/stainless brake lines | Lines, connectors, etc | Done | 2005Q4 |
| Re-wire LED voltmeter | None Required | Done | 2005Q4 |
| Repair Dash/Gauge Lights | Check wiring, bulbs? | Done, repaired short | 2005Q4 |
| Short in clutch lever/headlight | No parts needed | Done, tested - apparently solved during front-end rebuild | 2005Q4 |
| Repaint bucket, trees, clamps, gauge covers | Paint, primer | Done | 2005Q4 |
| Small front fender | Have LTD fender, need to modify/drill holes | Done | 2005Q4 |
| Install clock | Spot Clock | Done | 2006Q1 |
| Middle..................................................................................... |
| Adjust floats | No Parts Required | Done, Adjusted floats to 25mm from gasket | 2005Q3 |
| Replace crankcase-to-airbox hose | Hose | Done, Installed clear hose from hardware store | 2005Q3 |
| Replace Spark plug caps | Caps (already have) | Done | 2005Q3 |
| The "coil mod" | Already have all parts | Done | 200510 |
| Replace/reclamp fuel lines | Already have fuel line and zip ties | Done | 2006Q1 |
| Disassemble/inspect/clean petcock | None Required | Done | 2006Q1 |
| Fix horn | Ordered new horn from z1Enterprises | Done/installed | 2006Q1 |
| Repair stripped carb screws (M4) | Recoil set or tap set | Done | 2005Q4 |
| Tach seal leak | Top gasket, seal, etc | Done - Installed NOS gasket and stuffed 10mm o-ring in | 2005Q4 |
| Investigate auto-advancer | None | Done, cleaned/lubed | 2005Q4 |
| Oil fill cap leak | O-ring | Done, Replaced o-ring | 2005Q4 |
| Oil leak at, and adjustment of, cam chain tensioner | Investigate, adjustment | Done, Replaced o-ring, adjusted | 2006Q1 |
| Install new coil | Dyna 3.0 Ohm Coil DC1-1 | Done | 2006Q2 |
| Back..................................................................................... |
| Install/Change LED license plate ring | Plate Ring (already have) | Done | 2006Q1 |
| Modify/lift license plate | Fabricate plate bracket | Done | 2005Q4 |
| Install amber LED License Plate holders, wire with turn signals | LED Plate Holders | Done | 2006Q1 |
| Paint spokes | Have Satin Black from front spokes | Done | 2005Q4 |
| Rear fender eliminator | Have old fender, need to modify | Done - bobbed, may paint later | 2005Q4 |
| Repair swingarm looseness | Got new bearings from z1Enterprises.com ($33 for all four) and NOS sleeve from eBay ($45) | Done! Done! YAAAAY!!! | 2006Q1 |
| Replace luggage rack | Have rack, need u-shaped bolts | Done | 2005Q4 |
| LED/taillight indicator mod | Relay | No longer needed after adding LED plate ring |
| On-Going..................................................................................... |
| 12759 mile oil change, et al | Have oil, Emgo filter, magnetic plug | Done! | 2006Q2 |
| Replace rear shocks | Have nice shocks from eBay | Done | 2006Q3 |
| Valve adjustment | Got 32mm 2.40 shim from Howell Cycle, cheap tool from z1enterprises.com | Done | 2006Q3 |
| Replace front wheel bearings | From AllBallsRacing.com, Part #25-1221 $12.90 | Done | 2006Q3 |
| Replace rear wheel bearings | Ordered bearings from AllBallsRacing.com, Part #25-1286 $28.77 | Done | 2006Q3 |
| Winterize | No oil change, oil in cycl, deflate tires, up on blocks, remove/store tank | Done | 2006Oct(late) |
| Replace "coil mod" fuse with blade | Have blade-style holder and fuse | Done | 2006Dec |
| Investigate mis-aligned front end | None | Done? Loosened overly-tight stem, re-seated tubes and lowered a few MMs | 2006Jan |
| Replace Fuel line and filters | Have 1/4" GoodYear fuel line, need new filters from z1 | Done | 2007Mar10 |
| Oil and filter change | Have Emgo filter and Rotella | Done at 13861 mi | 2007Mar10 |
| Starter Clutch Explosion! | Scavenged starter clutch from spare 400 engine | Done - installed spare with no pins, rollers, or springs | 2007May6 |
| Oil change (after starter clutch problem) | 3q motorcycle oil, and Rotella | Done at 14309 mi | 2007May6 |
| Re-do relay coil power | Replace cheap relay with Bosch and pigtail, fixed secondary power to ignition | Done - with new 12 ga. wire, cleaned up, better solders | 2007Aug25 |
| Upgrade Fusebox | Have fusebox, blade fuses | Done | 2007Aug25 |
| Re-Set floats | Old setting (see above), was too high | Done - set to 26mm from outer carb edge, not gasket surface | 2007Aug25 |
| Oil and filter change (and chain clean and lube) | Emgo filter and Rotella | Done at 16070 mi | 2007Sep03 |
| Morgan Colortune adjustment | None | Done | 2007Q4 |
| Check valve clearance, REPLACE GASKET | Have gasket | Done, used sealant at rubber caps | 2008Apr25 |
| Replace fuel filters | Have larger filtersfrom z1enterprises.com | Done | 2008Apr25 |
| Oil leak at, and adjustment of, cam chain tensioner | Found missing washer and improperly machined bolt! Ordered new from bikebandit.com | Install, done! | 2008Apr25 |
| Oil change (and chain clean and lube) | Rotella | Done at 18260 mi | 2008Jul17 |
| Wrap STOCK (with x-over) exhaust headers (after oil leaks are fixed) | Remove rust, need high-temp paint and black fiber wrap | x | ... |
| Clean tank in dryer with BBs | BBs | x | ... |
| disassemble and clean front caliper | x | x | ... |
