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Projects/Maintenance for Bike #3, the Second 750
ItemPartsWork PerformedCompletion Date
Get it startedPatienceIt's running!! On the road at ~9200 miles on the clock2006Q2
Oil Changeoil, filterDone, ~9200 mi2006Q2
Adjust carb floatsnoneDone, adjusted to 26mm from surface2006Q1
Chain and sprocketsHave Parts, Lockwasher from z1Enterprises, Sunstar sprocket from DennisKirk (has lockwasher hole)Done2006Q2
Replace crankcase-to-airbox hoseHose from hardware storeDone2006Q1
Unfreeze rear brake pistonNoneDone2006Q2
Install SpeedBleeder and bleed rear brakeHave speedbleeder and brake fluidDone2006Q2
Install SpeedBleeder and bleed front brakeNeed speedbleeder (ordered) and brake fluidDone2006Q2
Check/Replace tail & turn lights/lenseHave old bulbs and lense somewhereDone2006Q2
Tank clean and re-installDepends on cleaning solutionDone! Electrolysis and Acid2006Q2
Replace brake lenseHave lenseDone2006Q2
Install tach cableneed cable (ordered from DK)Done2006Q2
Replace all dash lightsneed bulbs (1445 3/4 watt?)Done2006Q2
Front tiretire (D404F 100/90-19 57H), tubes, strapsDone by Howell Cycle2006Q2
Rear tiretire (D404 120/90-18 65H), tubes, strapsDone by Howell Cycle2006Q2
Fuse box boltboltDone2006Q2
Check, lube, adjust throttle/clutch cableslubeDone2006Q2
Check fork oil and sealsHave fork oilDone2006Q2
Insure, license, ride!noneDone2006Q2
Re-evaluate wiring, search for charge losses and gremlinsHave wire, etcDone - Sanded & resurfaced rear grounds, ran new main harness ground, cleaned and fixed front end2006Q2
Set timing/pointsnoneDone2006Q2
Install standard seathave seatDone2006Q2
Coil modHave relay, wireDone2006Q2
Elec. Turn signal relayNeed relayDone2006Q2
MirrorsHave Bar-end mirrors?Done - Just fixed crappy old mirrors2006Q2
Battery strapneed strapDone!2006Q3
HandlebarsI HATE the stock bars. Superbike? Yes/no?Done - Went with the Daytona model2006Q3
Install case guardshave guardsDone2006Q4
Replace oil fill cap o-ringo-ringDone2006Q4
New coilneed Dyna 5.0 Ohm Coil DC8-1Done! Best mod of all.2006Nov11
New fuel lines & filtersGoodYear 1/4" line from AutoZone, filters rom z1enterprises.comDone2006Nov11
WinterizeOil/filter Change @ 10871 mi, oil in cyls, tires deflated, up on blocks, remove/store fuel tankDone2006Dec3
Replace "coil mod" fuse with bladeHave blade fuse and holderDone2006Dec
Replace clutch padsHave EBC clutch new pads and platesx?Done2007May26
Investigate starter clutchFound sheared bolts, removed strarter clutch assembly, starter sprockets, and chainDone2007May26
Clean tank in dryer with BBs1500 BBs, naval jellyDone2007May27
Petcock repairClean/Rebuild petcock with rebuild kitDone2007May28
New fuel lines, filtersNew fuel lines, filtersDone2007May28
The stock exhaust must go!Might have mufflers, must checkCut off stock mufflers, fiber-wrapped stock headers, installalled angles, used old 400 Jardines, started for first time this season - DONE!2007June3
Replace headlightNew headlight from z1enterprisesDone2007Oct
WinterizedOil change at 11912 miles, Fram filter with figure-8 o-ring and replaced outer oil bolt o-ring, tank filled to top with Stabil added, bowls drained, oil in cyl, tires to 20lbsDone2007Nov18
Replace fork tubesGot forks from eBayInstalled forks a few mm's higher than normal, painted bracket, cleaned up, etc.2008Jan05
Check fork oil in new forksNothingThey were way over-filled. Drained excess, checked, done!2008Mar08
Upgrade FuseboxHave fusebox, blade fusesDone2008Sept01
Need to adjust chainNoneDone2008Sept01
WinterizeNoneRemoved 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
Oil ChangeRotella oilDone, 13240 mi2009Mar15
Check valve clearance and replace gasketHave gasketDone, recorded values on info page2009Mar15
Un-winterizeFuel lines, filterCleaned carb parts a bit, tank on, fuel lines and filter, battery, runs great, Done2009Jul04
WinterizedOil change at 13919 miles, Fram filter, carbs removed for cleaning, oil in cyl, tires to 20lbs, on blocksDone2009Oct17
Change main jetsOrdered some 130 main jets from ebay, part 92063-147Installed the new #130 main jets (main jets are accessed in bowl, externally, from behind the drain screw, with a small screwdriver), Done2010Feb10
Replace broken two long bolts on sprocket side coverOrdered 2 new long bolts for each bike 130G0695 Drilled, removed, replaced; Done2010Apr03
Touch up header paint on bikeNoneDone2010Jul10
Change pilot jetsGot 2 MIKUNI PILOT JET BS30/96 #47.5 7.95 each from motorcyclecarbs.comInstalled, done!2010Jul31
WinterizedOil change at 15403 miles, Emgo filter, carbs bowls drained, oil in cyl, tires to 20lbs, on blocksDone2010Oct03
Un-WinterizedSpring is here!Done2011Apr23
Replace headlightBought "brighter" headlight onlineDone2011Sep
Fix fuel leakSince un-winterization, lots of fuel overflowCleaned float needle and seats (just with q-tips), disassmbled petcock (still looks good in there) and steel-wooled the "cone" inside; Done2011May07
WinterizeOil changed at 16203 mi, Emgo filter; Battery topped off, brought in house on tender; Carb bowls drained; Tank drained, added 2-cycle oil, brought in house; Oil in cyl's; Tires to 20 lbs **Need new air filter; have? Done.2011Oct23
WinterizeOil changed at 16566 mi, no oil filter; Battery topped off, brought in house on tender; Carb bowls drained; Tank drained, added 2-cycle oil (and others), brought in house; Oil in cyl's; Tires to 20 lbs, new Gold Plug magnetic oil plugDone.2012Oct
WinterizeOil changed at 17185 mi, Fram oil filter; Battery topped off, brought in house on tender; Carb bowls drained; Tank drained, added 2-cycle oil (and others), brought in house; Oil in cyl's; Tires to 20 lbsDone with M2013Oct20
Un-WinterizedHad failed spark plug (replaced bothwith old ones). New left-side foot peg grommets. First commute, May 30thDone2014May26
WinterizeOil changed at 17750 mi; Battery topped off, brought in house on tender; Carb bowls drained; Tank drained, added 2-cycle oil (and others), brought in house; Oil in cyl's; Tires to 20 lbsDone with M2014Nov01
Un-WinterizedEasy peezy.Done2015May25
WinterizeOil and filter (Emgo) changed at 18550 mi, with new 8-ring (92055-084); Battery topped off, brought in house on tender; Carb bowls drained; Tank drained, added 2-cycle oil (and others), brought in house; Oil in cyl's; Tires to 20 lbsDone2015Oct17
Un-WinterizedReplaced fuel line/filters, installed tank, air in tires, tightened/connected plugs, and installed new battery. I mean brand-new!Done2016May30
Replace hard handlebar dampersBought 92075-275 handlebar dampers from jessbikes on eBayInstalled, tightened only enough to get pins in, to see if it damps more2016Jul17
Install 1/2 Dyna ignitionSee reportInstalled, lightly tested2016Aug20
WinterizePre-ridden with fuel treatment, oil changed at 19269 mi; Battery was not topped off (replaced early season 2016), brought in house on tender; Carb bowls not drained(whoops); Tank drained, added 2-cycle oil (and others), brought in house; Oil in cyl's; Tires to 20 lbsDone 2016Oct29
Un-WinterizedReplaced fuel line/filters, installed tank, air in tires, tightened/connected plugs, and installed battery.Done2017May28
WinterizePre-ridden with fuel treatment, oil changed at 19440 mi; Battery topped off, brought in house on tender; Carb bowls not; Tank drained, added 2-cycle oil (and others), brought in house; Oil in cyl's; Tires to 20 lbsDone 2017Oct00
Un-WinterizedReplaced fuel line/filters, installed tank, air in tires, tightened/connected plugs, and charged/installed battery.Done2018Sep08
Install 7th Gear Designs electronic ignition7th Gear Designs Kawasaki KZ Series Ignition Systems, Part# KA-750-Ign-01, Item# 004, $287.50 USDDone, tested, grounded both advance curve control wires20180915
Change to LED brake/tail lightRadiantz LED red 1.85 cluster, part#3203-19, 1157 direct-baseDone2018Sep15
Stainless front brake lines, disassemble and clean caliper...
Replace fork seals on spare forksHave seals, covers...
Replace bottom engine bolt after case guard change10x325 bolt part no. 92001-1654 and 10mm lock nut...


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Pilot screws were 1 3/4 turns out, but as of 20070806 Pilot screws are 2 turns out... changed to 2 1/8 20070812 ... changed to 2 1/2 turns out 20080830 (and runs great)... changed temporarily to 2 turns out after jet change on 20100731...
Clean carb, definately replace float valve needles, ordered 2 1755 FLOAT NEEDLE: M1 MIKUNI from motorcyclecarbs.com on 20100801
Note 20101003; need to find a way to stop overflow fuel leaks. Maybe in 2011, new float bowl gaskets, install new float needles, and find a way to stop inline filters from bending so much.
Fuel still leaked all 2011 season, even after replacing everything except the float needles and seats... Maybe next year...
Also, for 2011, really need to change the air filter.
Got a new long engine bolt from ebay! Need to install...
Need air filter, cooling fin rubber spacers (part #92075-109 $1.61 @ Ron Ayers), oil filter washer (part #92022-1012)
2013 - need rubber footpeg bushings
2015 - Winterization notes: Tightened drive sprocket, missing all cooling fin spacers (4 per side), swapped batter to other bike, need to rebuild forks