| 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 |
| Oil change and filter (and chain clean and lube) | Rotella and GTX, Fram filter, replaced inner-most o-ring on filter bolt | Done at 19280 mi | 2009Mar14 |
| Battery fill-up | Dist. Water | Done | 2009Mar14 |
| Replace Fuel line and filters | Have 1/4" GoodYear fuel line, need new filters from z1 | Done | 2009Mar14 |
| New tires | Bought new Pirreli MT-66 from Motorcycle-Superstore.com | Changed by Howell Motorsports, installed at 19800 miles, Done | 2009May29 |
| Side covers | Got some G model sidecovers from eBay | Sanded/painted G covers green (in June), then wet-sanded, then primered, then painted satin black | 2009Sep12 |
| Wrap STOCK (with x-over) exhaust headers (after oil leaks are fixed) | Remove rust, use high-temp paint, black fiber wrap, MAC tapered mufflers | Done | 2009Sep12 |
| Grease swingarm bearings | None | Done | 20090920 |
| Winterize | Oil change (Rotella & V all-clim), oil in cycl, deflate tires, fill tank | Done | 2009Dec13 |
| Un-winterize | Bolts, plugs, jets | Air in tires, new NOS sidecover bolts (part 130G0695) on, changed plugs to BR8ES, new fuel lines and filters, installed 130 main jets (part 92063-147), set floats to exactly 25mm from outer lip, Done | 2010Mar06 |
| Oil/filter change | Rotella and Fram filter | Done at 22315 mi | 2010May29 |
| Remove grip warmers and replace grips | Replace old, ripped ProGrips with new | Done | 2010May29 |
| Lube throttle assembly and cables | None | Done | 2010Jun |
| Change pilot jets | Got 2 MIKUNI PILOT JET BS30/96 #50 2.75 each from z1enterprises.com | Installed, re-tapped 2 more float bowl screws, done! | 2010Aug11 |
| Winterize | Change oil (Rotella), filter (Fram), N.O.S. figure-8 o-ring, battery/tank removed, oil in cyls, tires reduced | Done at 23713 mi | 2010Dec04 |
| Winterize | Change oil (Rotella/Valvoline), filter (Emgo), battery (topped off)/tank (drained) removed, oil in cyls, tires reduced | Done at 24872 mi | 2011Dec04 |
| Cooling fin rubber spacers | Got and installed rubber spacers (part #92075-109 $1.61 @ Ron Ayers) | Done | 2012Mar04 |
| Un-winterized | Re-assembled | Done | 2012Mar04 |
| Change seat | Have seat, bought a while ago from eBay | Done | 2012Jun |
| Diagnose/Solve crazy engine rattle near stator | None | Disassembled, found 3 stator allen bolts to have backed out and loose, one completely out and rattling against rotor; re-installed with BLUE LocTite; oil (Rotella) and filter (Emgo) changed at 25299, istalled with new filter washer (92022-1012) and drain plug washer; Done | 20120728 |
| Winterize | Change oil (Rotella), battery (topped off)/tank (drained) removed, oil in cyls, tires reduced | Done at 25717 mi | 2012Nov10 |
| Un-Winterized | Replaced everything, and new fuel line/filters | A little bit of a fuel leak, going away over days. First commute: 4/4/13 | 2013Mar30 |
| New grips | Ordered "Grab On MC315 Deluxe Road 6" x 7/8" Grips with Chrome End Cap" from Parts House (Babbitts) | Installed, Done | 20130511 |
| Resolve popping on decel and poor idle | None | Dropped right bowl, cleaned out pilot passages, etc. Smooth idle is restored! Done | 20130518 |
| De-slacken and lube chain, and align wheel | None | Chain was fairly slack, tightened a bit and used steel ruler on sprocket to align; Done | 20130518 |
| Winterize | Change oil (Rotella) and filter (Fram), battery (topped off)/tank (drained) removed, oil in cyls, tires reduced | Done at 26655 mi | 2013Dec21 |
| Un-Winterized | Replaced everything, and new fuel line/filters, failed right-side spark plug replaced, new foot peg grommets and oil fill cap o-ring | A little bit of a fuel leak, going away over days. | 2014Mar30 |
| Check/Add fork oil | Already had 10w Fork Oil | Both fork legs were a few cm low, added 10w just above line, done | 2014Jul20 |
| Replace rear shck/spring units | Overweight/Oversized shock/springs from z1Enterprises.com: Hagon RS Shocks Standard 330mm KZ750B (HSSA-32006-330) with Hagon Chrome Spring 23kg/129lb (HSRS-CHROME-23) | M installed, done | 2014Jul26 |
| Attempt to fix fork binding | None | Loosened and re-tightened for and tree in order as described in manual - Better | 20140921 |
| Winterize | Change oil (Rotella) at 27588 mi, battery (topped off)/tank (drained) removed, oil in cyls, tires reduced | Done with M | 2014Nov15 |
| Un-Winterized | Replaced fuel line/filters, installed tank, topped/installed battery, air in tires, tightened/connected plugs, but did not start yet. | Will start in coming days. | 2015Apr12 |
| Aligned Chain | Got MotionPro chain alignment tool | Chain was out of alignment, aligned with tool | 2015Apr18 |
| Aligned Fork | Got MotionPro fork alignment tool | Fork was actually being forced apart, possibly from the fender | 2015Apr18 |
| Un-Winterized Part II | Started, checked for leaks, fresh fuel, test ride. | Runs great, rides great. | 2015May03 |
| Swap forks | Bought and installed: Tool - 57001-1011 from eBay (partzilla fulfilled), Seal - 92049-1216 SEAL-OIL,FORK OUTER (from Partzilla), Dust covers (44010-032x2)(from z1enterprises.com), with original fork tubes from #3 bike and kept #2 bike springs | Installed with 50/50 10w fork oil and ATF | 2015Jun27 |
| Fix wobbly dash gauges | No parts needed, used old padding | Installed cotton padding base behind speedo and tach (inside covers), and added second nut/washers for dash mount | 2015Jul04 |
| Winterize | Change oil (Rotella) and filter (Emgo) with 8-ring (92055-084) at 28601 mi, battery (topped off)/tank (drained) removed, oil in cyls, tires reduced | Done | 2015Nov22 |
| Un-Winterized | Replaced fuel line/filters, installed tank, topped/installed battery (switched, using battery that used to be in #3 bike), air in tires, tightened/connected plugs | Done. | 2016Apr?? |
| Replace hard handlebar dampers | Bought 92075-275 handlebar dampers from jessbikes on eBay | Installed, tightened only enough to get pins in, to see if it damps more | 2016Jul17 |
| Winterize | Change oil (Rotella) at 29890 mi, battery (topped off)/tank (drained) removed, oil in cyls, tires reduced | Done | 2016Nov20 |
| Un-Winterized | Replaced fuel line/filters, installed tank, topped/installed battery, air in tires, tightened/connected plugs | Done. | 2017May?? |
| Winterize | Change oil (Rotella) and filter (Emgo) at 30470 mi, battery (topped off)/tank (drained) removed, oil in cyls, tires reduced | Done | 2017Oct14 |
| Un-Winterized | Replaced fuel line/filters, installed tank, topped/installed battery, air in tires, tightened/connected plugs | Done. | 2018May27 |
| Operating failure | Bike exhibited electrical failure during commute and had to be towed | None | 2018Jul02 |
| Post-failure repairs | New reg/rect, stator wires replaced | Check all systems, replace reg/rect. (Ricks Motorsports Electrics SKU: RI10-304 from z1Enterprises.com, $104.95, 8/11), have stator checked and re-wired by RMStator 10/17 (otherwise fine) | 2018Summer |
| Winterize | At 30683 mi, battery (topped off)/tank (drained) removed, oil in cyls, tires reduced | Done | 2018Nov03 |
| Un-Winterized | Replaced fuel line/filters, installed tank, topped/installed battery, air in tires, tightened/connected plugs | Done. | 2019May27 |
| Winterize | HiFlo HF126 filter, OEM figure-8 O-Ring (92055-084) | At 31192 mi, battery stored, tank (drained) removed, oil/filter/o-ring change, oil in cyls, tires reduced -- Done | 2019Oct22 |
| Un-Winterized | Replaced fuel line/filters, installed tank, topped/installed battery, air in tires, replaced plugs with B7ES, topped off oil | Done | 2020May02 |
| Replace seat cover | Seat cover sent to me by forum member (who? I wish I remembered | Installed, tightened only enough to fit, see if it needs adhesive in spring | 2020Sep19 |
| Winterize | None | At 31296 mi (pandemic, doncha know), battery stored, tank (drained) removed, oil in cyls, tires reduced -- Done | 2020Oct04 |
| Replace old (2016) Lead/Acid Battery | Duralast Gold ETX15L AGM-type battery ($84.99) | Installed, removed old overflow line, Done! | 2021Apr25 |
| Un-Winterized | Replaced fuel line/filters, installed tank, air in tires | Done | 2021May01 |
| Winterize | Petcock replacement o-ring kit (200-2021) from z1enterprises.com -- it's the correct flat o-rings!!! | At 31665 mi, battery stored, tank (drained) removed, oil in cyls, tires reduced, petcock o-ring replacements installed -- Done | 2021Nov14 |
| Replace air filter | Got Fram CA-9248 from Amazon | Cut hole in bottom, installed | 20220813 |
| Winterize | Rotella-T 10W-40 Oil, Hi-Flo oil filter (no figure-8 o-ring this time) | At 31763 mi, oil changed, stored, tank (drained) removed, oil in cyls, tires reduced -- Done | 2022Nov11 |
| Un-Winterized | Replaced fuel line/filters, installed tank, installed battery, air in tires, topped off oil | Done | 2023Apr00 |
| Un-Winterized | Motion Pro 12-0052 Tygon Grey 1/4" x 3' Premium Fuel Line ($25 from Amazon) Filter - Fuel - 1/4 inch - Conical - Translucent ($6 from z1Enterprises.com), borrowed ETX15L AGM-type battery from other KZ750 | Replaced fuel line/filters, installed tank, installed battery (3-year-old battery was dead), air in tires, at 31940 miles - Done | 2024Jul05 |
| Winterize | Rotella-T blend of 10W-30 and 15W-40 Oil | At 32084 mi, oil changed, stored, tank (drained) removed, oil in cyls, tires reduced, chrome cleaned -- Done | 2024Oct04 |
| Add '78-style KZ750 badges to '80 style sidecovers | Got badges from ebay | x | ... |
| Clean tank in dryer with BBs | BBs | x | ... |
| disassemble and clean front caliper | x | x | ... |
