| "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 |
| Disassemble, clean, and inventory carbs (and jets) | Replacement o-rings (from mcmaster.com) and 130 main jets | Clean and Ibby-ized | 20090215 |
| Change/check clutch basket | Might use basket from original engine | Found notches in basket notch sides, smoothed with metal file and emery cloth, re-used home-made gasket | 2009Mar21 |
| Un-winterize, replace fuel lines, filters | Have filters, need fuel line | Re-installed carbs, tank, battery, changed to tiny fuel filters, and replaced some fuel line, started up and ran around block | 2009Mar22 |
| Invesigate float bowl leak | Gasket? | Replaced damaged left float bowl gasket o-ring | 2009Jun10 | |
| Oil change | Oil, filter | Rotella 15-40, Emgo filter, at ~25470 miles, Done | 2009Jun30 | |
| Ghost neutral problem | Have spare neutral position bolt, spring and pin from crash engine | Swapped, seemed to fix! Done | 2009Jul21 | |
| Floats check and jets change | Need to check float level wet, and have new 135 mains to replace 130s | Set floats to 3mm EXACTLY with wet method, which is 23mm dry method, set pilot screws to 1 5/8 turns out, and installed 135 mains. Done | 2009Aug26 | |
| Change taillight | Got early-style CL77 taillight from eBay | Done | 20090920 |
| Winterize | None | Removed battery, tbs 30w oil in cyls, tires to 20lbs, (soon to be up on blocks), tank drained and swished with MMO., brought tank in for storage, oil change(GTX, no filter) at 26683 mi | 20091128 |
| Clutch pusher repair project | Got new 6mm screws for engine sprocket guard from lawn-parts.com, and new NOS clutch cable | Disassembled left side cover, clutch push mechanism, cleaned, re-greased, re-assembled with lubed new cable and new screws, adjusted | 20100220 |
| Un-Winterize | None | Re-installed tank with new lines and filters | 2010Apr04 |
| Ghost neutral problem | Bought new neutral position spring and pin from bikebandit.com | Swapped, Done | 2010Jul10 | |
| Repair carb float bowl thread (where idle adjuster is) | Have repair tool and insert | Done! | 2010Nov28 |
| Dead battery | New Duralast battery | Done! | 2010Oct |
| Winterize | None | Removed battery, tbs 30w oil in cyls, tires to 20lbs, (soon to be up on blocks), tank drained and swished with MMO., brought tank in for storage, oil change (Rotella, Fram filter, both o-rings) at 27988 mi | 20101121 |
| Un-Winterize | None | Air in tires, carbs back on, fresh fuel, new fuel lines and filters, lube, etc.; runs great!! | 20110327 |
| Shim carb main jet needle | Ordered shims from z1enterprises.com | x | 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 | x |
| Check/install missing engine case screws | Screws | Still need one short screw | x |
Pilot screws at 1 and 5/8 turns out 20090826