| "To Do" list for Bike#4, the second 400 |
| Item | Parts | Work Performed | Completion Date |
|---|
| Valve adjustment | None | Done | 2006Q3 |
| Replace exhaust and repair stud | Use old MAC exhaust from other 400 | Done | 2006Q3 |
| Go over wiring | None | Re-soldered some cut and twisted wires | 2006Q3 |
| The coil mod | Relay | Done | 2006Q3 |
| Balance carbs | None | Done | 2006Q3 |
| Clean carbs with Yamaha Fuel treatment | None | Done | 2006Q3 |
| Install fuel filters | Already had filters | Done | 2006Q3 |
| Gas cap seal and assemby | Used parts from old tank | Done | 2006Q3 |
| Winterize | No oil change, oil in cycl, remove | Done | 2006Oct(late) |
| Repair seat | Vinyl repair kit | Done | 2006Nov |
| Replace bent handlebars | Bars, not sure which | Done - Installed old 750 bars | 2007Spring |
| Carb assembly is loose! I can tap at the top or bottom of the right carb and change the balance. | None | Found problem to be caused by floating piece of rubber (from old fuel lines?) above float jet | 20080831 |
| Oil change, et al | Castrol GTX, Emgo filter (and o-rings) | Done at 10536 | 20080831 |
| Front-end cleanup..................................................................................... |
| Fix fork seals | Found some unused seals lying around | Installed, re-used existing dustboots, filled with pure 10w fork oil to spec, Done | 2008Sept06 |
| Dismantle & clean front caliper, bleed system | Brake fluid, ordered Russel SpeedBleeders from Jegs.com | Dismantled caliper, scrubbed out gunk, re-assembled -- On-going bleeding of air, but done. | 2008Sept6 |
| Replace old *front* tire | Already have front D404 (100-18) and tube, had HC mount | They trued rim a bit as well, and I got it back on. Done. | 2008Sept6 |
| Rear-end cleanup..................................................................................... |
| Replace worn chain and sprockets | New RK w-ring chain and sprockets from z1enterprises.com | Installed with 16f and 44r, Done. | 2008Sept22 |
| Replace old *rear* tire | Ordered rear D404 110 from RonAyers, have HC install | Done. | 2008Sept22 |
| On-going..................................................................................... |
| Speedo doesn't work | Broken cable? Need new? | Got new from z1enterprises, installed, Done | 2008Sept4 |
| Missing mirror | Need stock-style mirrors | Found old stock mirrors in garage, installed, Done | 2008Sept6 |
| Custom PVC airbox | PVC components, 52mm pod | Assembled with PVC glue, Done | 2008Sept21 |
| Change sprocket ratio | Ordered w-ring chain, 16t front and 44t rear from z1enterprises.com | Installed, Done | 20080906 |
| Winterize | None | Tires to 20lbs, remove carbs, battery, drain and store tank, oil in cyls, up on blocks | 20081101 |
| Disassemble carbs, clean and document jets | o-rings from bikebandit.com and mcmaster.com | Completely disassembled, document jets, soaked bits in Seafoam, Ibby-ized bodies, replaced o-rings, ... | 2009Jan |
| Rusty tank | Clean with special trick | Shook up with chain, rinsed with "Prep & Etch", dried with hairdryer; New petcock gaskets and cleanout; Not perfect, but pretty good; Done | 2009Jun09 |
| Un-winterize | Tank clean, carbs tuned and balance | Done | 2009Jun09 |
| Headlight switch is flaky, can turn light off | Clean/repair, or just replace left-hand conrol unit | | TBD |
| Re-install main wiring harness fuse | 20 Amp blade fuse holder | | TBD |
| Investigate cheesy wiring hacks, repair as needed | None | | TBD |