Manual for Previous Owners

Painted surfaces: These should be scratched or chipped in some fashion. A dropped tool acheives excellent results. For any chipped or painted items that bother you, be sure to touch up with paint that almost, but not quite, matches the original color. Apply with sponge or rag. Use flat paint.

Electrical: Bend wires when disconnecting to near the breaking point. Reconnect. This is especially important on wires with short length near a terminal.

Fasteners: Use locktite on all threads and tighten beyond reason. Later disassembly: For hex bolts use the nearest non metric size wrench. For phillips screws, especically the engine covers, use a screwdriver slightly too small. Resort to pliers and vice grips when the screwdriver does not yield results. For all other nuts and bolts an adjustable wrench is sufficient when vice grips are not available. Now reassemble with the lock tite and tighten beyond reason once more.

Standing on the gas tank to reach high storage in the garage is an acceptable substitute to a ladder.

My PO was keen on following instructions...

 

Load rear carry rack to 300% of rated load. Carry large pillion passenger on every trip. Ride over every bump and pothole until frame fatigues under seat. Weld up using old bolts positioned so as not to be seen without removing rear mudguard. Repaint with gloss paint to further hide.

Repair carburettors using methods described in previous post. Ensure float drain screws are properly burred so that conventional phillips driver will not remove them.

Method for removal of all broken screws:

Drill off center to 50% of depth specified by stud extractor manufacturer.
Insert stud extractor.
Hit extractor with hammer until it bottoms out.
Apply torque to extractor using vise-grip pliers to ensure extractor enters hole on angle to axis of stud.

Correct torque for removal is indicated by breakage of extractor in stud. If such torque cannot be achieved by hand, request assistance from very large friend or use pipe extension on wrench until correct indicated torque has been achieved.

Give bike to friend.
Catch next plane to New Zealand and get married.
Remind friend in Australia at every opportunity what a great mate you are for giving him your bike.

 

Dang, I've got hoodwinked from those guys and have bought bikes from both....although iandmac's PO reminds me of a kid that was here not too long ago and broke off the extractor in the head.....then he disappeared.
LOL


jeff

 

As an Electrician, I'd like to add these:
All joints to be made by twisting copper strands and covering with insulation tape. This is especially important in areas such as the sidestand cut out and regulator/rectifier.
Repair faulty moulded connector plugs by bridging with wire of a smaller cross sectional area that the original (A good weight-saving strategy).
Do not use auto wire - use conductors stripped out of domesic flex, preferably the green/yellow earth wire.

Sell the bike quickly.....

 

You absolutely do not need that little black box with the glass tube things in it. Cut it out and hardwire everything together. You will never have to worry about a pesky blown fuse again.

 

Wash it to death then park it? so th exhaust rusts out real quick and the engine goes grey as soon as possible. Apply so much polish to ignition switch that it has to be dismantled and cleaned so it will work. Don't normally PO bash but those two really annoyed me.

 

Hey, Mav, do you live in Michigan? I think we had the same PO!


Would also like to add as an adendum, When repainting motor it is not necessary to mask ANY of the surrounding area, i.e., headlight, gauges, horns

 

An Air filter on a street bike. Your joking, right? The streets are paved, not dirt!

And

Was going to change the oil, but couldn't get the filter off! See above for proper bolt tightening procedure!

Ghost

 

Nope im in New York but I have had to put a fuse box in my xj750, this winters trike project the xs400, and a couple friends bikes a xj650 and a radian.

the 750 came with over spray on the engine as it is obviously better to paint body parts on the bike rather than take them off.

 

Remove and replace float bowls back to front or similiar so as drain screws cannot be seen or reached ?