"How To" threads <lots of pics> - TwoWheelForum: Motorcycle and Sportbike forums
 
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post #1 of 15 (permalink) Old 06-11-2007, 04:25 PM Thread Starter
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Lightbulb "How To" threads <lots of pics>

Ok... so I have did ALOT of these for the big dog stuff. It gave me a chance to learn even more, cause teaching is the best learning tool for the teacher, by making them. Practice short and detailed shots and writing help on the internet.

Now granted it might not be as easy or maybe not as detailed say from a Yam to a Kaw how to. But the general idea could be done.

Further, I will post the longest and best one I have done. Everybody loved this one, cause you would be surprised how many people are scared to work on a $35,000 bike. Even if it is just a oil and service.




-Chris
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post #2 of 15 (permalink) Old 06-11-2007, 04:28 PM Thread Starter
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My "How to service your big dog"

Quote:
First get the bike up off the ground if possible...


The lets work on some of the little stuff.

Lube your cables.

Clutch.

Spray the clutch cable at the top by pulling the lever in and spraying in the cable lining




Spray some lube down the top of the cover to help slide it up and out of the way.



This is what you'll see



Losen the lock nut and spin the clutch cable loose



Spray some lube in the hole. I do this many times to allow it to work down the cable.



Also lube your throttle cables. Only one spot to get lube down the cable... at the grip. Loosen the lock nuts and spin the cables free. You'll have to do one at a time cause it will tighten the other. I do this about 4 times just like the clutch.




Brakes are a vital piece to the whole puzzle. So not only will we inspect the pad wear on the front and rear. We will ensure proper use by observing the caliper functioning up close. This may require somebody else to press the appriapriate lever. Then we will remove the resevior covers and make sure both are full.

Front:


Rear:


Get your air filter set right.
Removing your teardrop cover to gain access to the filter.



This would be a used/dirty K&N. I will simply clean it and re-oil it. But your paper filter may look similar and needs to be replaced.



Beverage time.

By now you should have your throttle cables put back together and adjusted the freeplay. Now lets check to make sure it is working properly and that your jets are spraying correctly.




I usually have to clean this off a bit. But with the filter off it will give you a good chance to check the jets and lube the throttle cables that are hooked to the side of the carb.

Plus ensure that your throttle is closing and opening freely. It is good to check it with your bars turned both ways to ensure no binding.

Onward to the oils...

Check your oil level and condition of your engine oil by pulling the dipstick. Ensure when always checking oil level that the bike is level and off the kickstand.


Lets first drain the engine oil. Pull the oil plug from the bottom of the oil tank.

Left/kick stand side of the bike next to the rear end of the rear shocks.


Inspect the plug and the metal fragments on the end of the plug. The plug is magnetic to catch shavings from your motor oil.


While that is draining. Pull, check and clean your tappet screen. It is located on the right/exhaust side of the bike. Above the oil pump and in front of the drive belt pulley.



Remove with some needle nose pliers but use caution. It should come out with ease.




I clean it with brake clean and let it air dry for a min. Enjoy a beverage!

Re-install the tappet screen. This takes a bit of finese. First try it with just the nut cover so you get the feel for how it goes in. Now try it with the screen and the spring. I used a socket and extension to aid putting it in. Use one hand to keep pressure down and the other to spin.

If the oil is done draining from oil tank. Put the plug back in. I like to use a dab of high temp rtv silicone on the plug to ensure a good seal. And torque it to specs (10ft lbs) Then refill the oil with 3 qrts of oil of choice.


Now time to remove the engine oil filter.

Remove crank sensor. Clean and inspect.



This allows for easier removal of the oil filter.

Beware. You may want something to catch this oil coming out soon. Or alot of rags for clean up or both.

Spin off...



OPTIONAL PHASE for those with a Scavenger Complete Oil System
http://www.roguechopper.com/

Spin on scavenger unit.


Start bike at idle and pump out the rest of the old oil that is still in your system. I removed about a extra quart of black black dirty oil.

See what you're wouldn't be getting out.


This is at about a 1/2 a quart into the evacuation of the old oil



Now onto what we all have to do...

Remove your new oil filter from the package, apply a little bit of new oil to the new oil filter o-ring and spin onto the bike.




Check oil level in oil tank top off as nessicary. Start bike again to wet down the system. Allow to set.

Time to have another cold beverage.

Check oil level again and top off as nessicary. Remember its easier to keep adding a little versus trying to remove if you add too much.



-Chris
aka Gas Man



Was: 2002 Kaw ZX-9R
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is me till the
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post #3 of 15 (permalink) Old 06-11-2007, 04:28 PM Thread Starter
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Continued
Quote:
Tranny oil.

Going to need to fab something to catch the oil coming out of the tranny. I cut up a old 2 liter plastic pop bottle.



Also get your 20 oz of tranny oil ready. By pouring out some from a full quart to a old quart. Like so...




Pull the tranny dipstick and check the oil level and condition.



Pull the tranny drain plug. Located under the bike just in front of the front drive belt pulley.



As you are spinning the last few threads off on this drain plug.. have your pan or 2-liter catch ready... like so...




As this is draining pull, inspect, clean, and re-install your speedo sensor. It is located under your seat, in front of the starter, on top of the tranny.




Enjoy a cold one. The tranny oil is thick and drains slowly unless warm.

Replace drain plug into the tranny and consider using the dab of silicone as stated above with the engine oil drain plug.

Now add your 20oz of tranny oil in thru the dip stick hole like so.



Primary time

Remove inspection plate to check level and condition of the oil.




Now you may notice that I removed the sponge and filled the seeping hole on the top with silicone. There is no need for it with the eye hole breather on the backside of the inner primary.

Lets continue.

You can see on these new 2006 models that you can't hardly inspect the chain lash/freeplay or much else. The derby covers are decorational and don't remove to gain access. So I always remove the outer primary if any adjustments are needed to the primary chain.

Either way, we need to drain the oil. By simply removing the primary oil drain plug located towards the rear of the bike just in front of the kickstand.



Inspect the drain plug and its magenet. Take notice to the shavings on it as well.



My bike is still pretty new and this being the end of my riding season decided to pull the out primary. Be prepared to have excess oil come out as you remove thie cover. Have rags handy!



Should probably have one last beverage of choice before finishing.

Check the chain lash/freeplay and adjust using the nut in the center of the primary. The chain should have from 5/8 - 7/8 inch of lash/freeplay at its tightest spot.

Clean the inside of the primary and its outer cover. Inspect and replace as you see needed the outer primary cover o-ring. Mine looked good so I just dabbed a little silicone around it and place the cover back on the bike. Torque the cover bolts to 108 inch lbs or about 9 ft lbs.



Add 1 quart of primary oil to the primary thru the inspection hole.



Replace the inspection cover and torque those to the same torque specs as the outer primary cover bolts.

Finish off that 6-pack right about now.

Now as I said I was winterizing. So I also before all of this ran fuel stabalizer thru the gas tank for a good 5 miles prior to this service. Then once done with all of this. I remove the spark plugs and spray a small bit of penetrating spray lube into the cylinders. You can use alot of different kinds from WD40 to the same lube you use on the cables. Just a bit of something to sit on top of your piston rings during its winter slumber. I also put the battery on a battery tender and cover the bike. If you have a lift I suggest storing it there to keep the tires off the cold ground.

In the spring, I will start the bike. Bring it to temp. Check for leaks. Check the tire's air pressure. Take it for a small spin around the block. Check again for leaks. If all good. Take it for a heathly ride. Once you return and the bike cools. Replace the spark plugs.

I tend to run a few tanks of gas on the "winterized oil change" then change that oil again just as stated above. Then you and your bike should be ready for a good riding season.

I hope this helps or at least gives some different perspective. I'm not endorsing my method over anybody elses or any of the products shown. I just thought it would help for all those guys that a bit scared to work on their $30,000+ bikes. Its simple and easy. Can be done within a afternoon even with beveerage breaks and done with a normal set of tools.



-Chris
aka Gas Man



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post #4 of 15 (permalink) Old 06-11-2007, 04:30 PM Thread Starter
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So after I wrote that one I did a bunch more... everything from changing out your exhaust, replacing baffles, pulling your carb, changing jets, turn signals... then more guys started doing them. Change out the front forks, swap out wet primary for open belt... all How To's to help the other rider.

I got so many and continue to get props from even old timers for this. Many say it graces the inside of the service manual. I have heard comments as far as "Gas Man you should write the service manual for BD cause your how to is way better". I chalk it up to being patient and passionate about my bike and riding. Add that with my detail orientated personality and ALOT of pics!! A pic is worth alot when doing project like these!!

Why don't some of you folks start doing this on the sportbikes? You see what I'm talking about... do your service or mod, take not just before and after shots.. .but exactly what you're doing and why.

Or is this too much work for peeps?




-Chris
aka Gas Man



Was: 2002 Kaw ZX-9R
IS:


is me till the

Last edited by Gas Man; 06-11-2007 at 04:32 PM.
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post #5 of 15 (permalink) Old 06-11-2007, 04:37 PM
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Yes, I am lazy!!.... Nah thats a good idea, I'll try to slow down enough next I am doing sumtin worthy of a how to on the bike. Most peeps will think its too much of a hassle tho. I know first hand it can be, but I've done a few computer related how to's. A lil patiennce and thought is all tats needed and ok maybe a lil computer saaviness.
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post #6 of 15 (permalink) Old 06-11-2007, 04:40 PM
 
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Quote:
Originally Posted by Gas Man View Post
Or is this too much work for peeps?
I don't think it's too much work... I think maybe some people will be afraid of a lot of eye-rolls for explaining something so carefully that many might think is simple..

I would do it though. Not too difficult
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post #7 of 15 (permalink) Old 06-12-2007, 12:47 AM
 
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GREAT idea, MOAR!!!
I wish someone would make a complete maintenance tutorial like this for my bike.
Possibly have a nice little business idea there? A photo book or video on the basic maintenance and modding practices of some popular bikes? I'm sure it's done to some extent but you're pretty good.
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post #8 of 15 (permalink) Old 06-12-2007, 03:51 PM Thread Starter
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Thanks man! I put ALOT of time into that one!! ALOT




-Chris
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Was: 2002 Kaw ZX-9R
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post #9 of 15 (permalink) Old 06-12-2007, 04:45 PM
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Thanks for the post.
Great detailed work.
Shinny too.
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post #10 of 15 (permalink) Old 06-12-2007, 09:26 PM Thread Starter
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Yeah I am just using my service how to as a great example...

We need to get some peeps to do this stuff on some standard sportbike stuff. Oil changes, complete services, coolant swaps, fork rebuilds and fluid change, stuff like that!




-Chris
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Was: 2002 Kaw ZX-9R
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post #11 of 15 (permalink) Old 06-12-2007, 09:30 PM
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and this is why you are my mechinac over the phone attention to detail and vast knowledge



"It takes alot of anything to make my bike to something"
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post #12 of 15 (permalink) Old 06-12-2007, 09:35 PM
 
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Quote:
Originally Posted by Gas Man View Post
Yeah I am just using my service how to as a great example...

We need to get some peeps to do this stuff on some standard sportbike stuff. Oil changes, complete services, coolant swaps, fork rebuilds and fluid change, stuff like that!
Gas it would be nice to have a whole 'how-to' section, especially for newer members or members who arent comfortable working on their bikes. Check out the way r6messagenet.com does theirs, it's extremely helpful, and the guys keep a running sticky of all the completed how to's... also there is a part fo the how to forum for people to request a how to. Something like that would really add to our forum here
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post #13 of 15 (permalink) Old 06-12-2007, 10:57 PM Thread Starter
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Quote:
Originally Posted by drewpy View Post
and this is why you are my mechinac over the phone attention to detail and vast knowledge
And I'm glad to help... just like my offer to help with the possible zixxer rebuild

Quote:
Originally Posted by ceo012384 View Post
Gas it would be nice to have a whole 'how-to' section, especially for newer members or members who arent comfortable working on their bikes. Check out the way r6messagenet.com does theirs, it's extremely helpful, and the guys keep a running sticky of all the completed how to's... also there is a part fo the how to forum for people to request a how to. Something like that would really add to our forum here
Well we need to get a fee of these sportbike how to's before we worry about sub forums....




-Chris
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Was: 2002 Kaw ZX-9R
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post #14 of 15 (permalink) Old 06-16-2007, 09:19 AM
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Quote:
Originally Posted by Gas Man View Post
Well we need to get a fee of these sportbike how to's before we worry about sub forums....
I think we already have a couple... Tire removal ones come to mind...

Oh, and you forgot a step in your process there Gas... "Spend the next two days polishing"...

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post #15 of 15 (permalink) Old 06-17-2007, 12:11 AM Thread Starter
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I spent two days cleanin/polishing... and now its all dirty again!!




-Chris
aka Gas Man



Was: 2002 Kaw ZX-9R
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is me till the
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