| 2009 | ||||||
|---|---|---|---|---|---|---|
| Date | Mileage | Service | Mechanic/Shop | Price | Notes | |
| March 2, 2009 | 14,368 | Initial inspection | Ian Johnston | $0 | Clutch slips due to weak springs (PO says they're new); unknown electrical problem(s) causing weak headlight, taillight, charging; steering stiff and notchy; tires from 1990 or so; front tire has raised center strip which may contribute to handling problems; chain is rusty in spots, but doesn't appear to bind; otherwise excellent condition | |
| March 3, 2009 | 14,368 | Checked steering bearing | Ian Johnston | $0 | Steering bearing has comically strong center detent, and feels very tight. Best theory is some PO (probably the one who installed the CB200 front end) tightened the bearing way too tight. Roller bearings on the way. | |
| March 3, 2009 | 14,368 | Swapped carburetors | Ian Johnston | $0 | Replaced original carburetors (which may or may not have bad needles) with racebike's stock, known good carbs | |
| March 4, 2009 | 14,368 | Installed ground jumper to new-looking rectifier | Ian Johnston | $0 | New rectifier (likely from Oregon Motorcycle Parts) didn't connect negative terminal to ground. This caused numerous problems including dim headlight and taillight, non-functional turn signals, and poor or no charging. Lights only operated when the engine was running. The rectifier ground point is one of only two unswitched ground-to-frame connections. | |
| March 4, 2009 | 14,368 | Adjusted valves | Ian Johnston | $0 | Adjusted all valves to .002 inches | |
| March 4, 2009 | 14,368 | Checked compression | Ian Johnston | $0 | Compression looks good: Left: 146 psi; Right: 145 psi | |
| March 10, 2009 | 14,368 | Replaced rear brake pedal | Ian Johnston | $0 | Used the one which came off the race bike. Original pedal was bent. | |
| March 10, 2009 | 14,368 | Replaced rear shocks | Ian Johnston | $0 | Used the Redwings which are take-offs from the race bike. Also removed the swingarm, and cleaned/lubricated everything. | |
| March 29, 2009 | 14,368 | Replaced steering bearings | Ian Johnston | $50 | Used new tapered roller bearings from Les Barker. Ended up having to use half of the plastic shim that came with the kit -- perhaps the '73 steering stem is slightly larger than the earlier ones. | |
| March 29, 2009 | 14,368 | Replaced front tire | Ian Johnston | $70 | Installed Bridgestone BT-39ss and new tube. | |
| March 30, 2009 | 14,375 | Added 5mm clutch spring preload spacers | Ian Johnston | $0 | Turned from .75" 6061 bar stock. | |
| March 30, 2009 | 14,427 | Replaced rear tire | Ian Johnston | $70 | Bridgestone BT39ss, new "King's Tire" tube. | |
| April 8, 2009 | 14,427 | Replaced clutch friction plates | Ian Johnston | $beer | New 3.0mm thick clutch plates and spare steel sent by M. Batemann. Clutch now has 6x 3.0mm friction plates, 5x flat steels, and one A plate (concave steel). Stack height is now 1.74mm below end of outer clutch basket fingers. 5mm preload spacers removed. Les Barker (gold) race springs installed. | |
| April 13, 2009 | 14,463 | Replaced carb fuel feed lines | Ian Johnston | $2 | Used generic Tygon fuel line from McMaster-Carr. | |
| April 14, 2009 | 14,463 | Installed 20mm preload spacers in forks | Ian Johnston | $.50 | Used .75x.125" aluminum tubing. Forks now sag around 1" instead of nearly 3". | |
| April 14, 2009 | 14,557 | Installed Pertronix electronic ignition | Ian Johnston | $125 | Purchased from Bateman Racing; removed points and condenser. | |
| April 29, 2009 | 14,557 | Installed new tach drive oil seal | Ian Johnston | $2 | none | |
| June 7, 2009 | 14,638 | Lubricated drive chain | Ian Johnston | $0 | none | |
| June 7, 2009 | 14,638 | Adjusted tire pressure | Ian Johnston | $0 | 30 PSI front, 35 PSI rear; rear tire was noticeably warmer than front at 30/30. | |
| June 28, 2009 | 14,760 | Installed new handlebars | Ian Johnston | $27 | Installed Street Master Drag Bars | |
| July 2, 2009 | 14,854 | Installed new drive chain | Ian Johnston | $27 | RK 428 plain chain, 57 sideplates/114 links (including master); old chain had one sideplate so worn out there was a ~1mm gap visible around the pin! Yikes! | |
| July 3, 2009 | 14,869 | Installed new throttle cable | Ian Johnston | $30 | none | |
| July 19, 2009 | 14,960 | Adjusted valves | Ian Johnston | $0 | Intake valves required noticeable adjustment; clattering noise eliminated | |
| July 19, 2009 | 14,960 | Lubricated drive chain | Ian Johnston | $0 | Chain tension was correct | |
| August 22, 2009 | 15,183 | Replaced carburetors | Ian Johnston | $175 | Installed Keihin PE24 carburetors, using new intake runners Jesse and I had built last year for the racebike conversion to PE24s. No more leaking float bowl FTW. | |
| 2010 | ||||||
| Date | Mileage | Service | Mechanic/Shop | Price | Notes | |
| March 3, 2010 | 15,286 | Rebuilt engine | Ian Johnston | $60 | Tore down, cleaned and inspected whole engine. Slightly bent crankshaft oil baffle to prevent rattling. Replaced majority of gaskets. Replaced most oil seals (only missed the timing cover oil seal). Replaced top-end locating dowels. | |
| March 3, 2010 | 15,286 | Installed adjustable camshaft | Ian Johnston | $5 | Built camshaft sprocket adapter and timed camshaft to 105° lobe centers. | |
| March 14, 2010 | 15,326 | Re-worked valve seats; 60°, 46° and 30° | Ian Johnston | $0 | Left cylinder required substantial cutting to center valve seats. This may or may not explain various odd imbalance problems with the engine. | |
| March 14, 2010 | 15,326 | Swapped piston rings | Ian Johnston | $0 | I had previously installed pistons with oil and compression rings swapped. Also rehoned bore with 2" Flex-Hone as long as I had it apart. | |
| March 14, 2010 | 15,326 | Installed new valves | Ian Johnston | $35 | Used NOS valves from Thaiger Motorsports in Thailand. | |
| March 21, 2010 | 15,401 | Checked compression | Ian Johnston | $0 | Bike is still smoking and pressurizing crankcase. L cylinder was 140 PSI measured hot; R cyl was 136 PSI. L sparkplug was slightly oil fouled; R plug was nice and tan. | |
| April 12, 2010 | 15,406 | Front brake reworked | Metal Frictions | $135 | Drum turned, pads re-lined | |
| May 8, 2010 | 15,406 | Bored cylinders to .50mm overbore | Autosport Seattle | $153 | Boring done by Autosport Seattle. | |
| May 8, 2010 | 15,406 | New .50 over pistons, wrist pins, circlips, rings | Ian Johnston | $120 | NOS Ebay pistons and rings, new Honda production wrist pins and circlips. All rings had end-gap of .007-.008" | |
| June 13, 2010 | 15,626 | Tightened steering head bearing | Ian Johnston | $0 | Bearing was shifting under braking and over bumps. Tightened considerably -- perhaps 1/2 turn from where it was. | |
| December 4, 2010 | 16,057 | Lubricated drive chain | Ian Johnston | $0 | none | |
| December 10, 2010 | 16,084 | Added about 250 ml engine oil | Ian Johnston | $0 | none | |
| 2011 | ||||||
| Date | Mileage | Service | Mechanic/Shop | Price | Notes | |
| January 14, 2011 | 16,127 | Added about 250 ml engine oil | Ian Johnston | $0 | none | |
| January 14, 2011 | 16,127 | Adjusted drive chain tension | Ian Johnston | $0 | Required 1.25 turns | |
| February 7, 2011 | 16,263 | Checked cylinder compression | Ian Johnston | $0 | 170 PSI left cylinder, 180 PSI right cylinder | |
| February 7, 2011 | 16,263 | Replaced spark plugs | Ian Johnston | $5 | New B8HS plugs. Old plugs were ok, but a bit scaly. | |
| February 7, 2011 | 16,263 | Replaced horn | Ian Johnston | $0 | Used discarded horn from Ninja 250 race bike; old horn had ceased working after brief period of intermittent function | |
| February 7, 2011 | 16,263 | Replaced instrument backlights and neutral light | Ian Johnston | $5 | Used 1891 bulbs for back lights, and 1445 bulb for neutral indicator | |
| April 24, 2011 | 16,316 | Replaced left rear turn signal housing | Ian Johnston | $0 | Old one was broken in a parking tip-over (thanks anonymous Capitol Hill drunk!). Replaced with one from the race bike. | |
| April 24, 2011 | 16,316 | Added 300 ml engine oil | Ian Johnston | $1 | Oil was off the end of the dipstick | |
| April 24, 2011 | 16,316 | Cleaned carburetor idle jets | Ian Johnston | $0 | Backfiring problem a few months ago had grounded the bike. Starts and runs much better. Idle jets were nearly completely clogged with varnish. | |
| May 12, 2011 | 16,318 | Replaced exhaust gaskets | Ian Johnston | $10 | Previous carb cleaning revealed exhaust leak -- discovered that the left exhaust gasket was completely gone. Replaced with new-manufacture copper exhaust gaskets. | |
| May 21, 2011 | 16,318 | Cleaned carburetor idle jets again | Ian Johnston | $0 | Needed to be cleaned again after sitting for a month. | |
| May 21, 2011 | 16,318 | Adjusted valves | Ian Johnston | $0 | Exhaust valves were quite loose, particularly the left exhaust valve. Intake valves were close, but still a bit loose. Hopefully I didn't burn the left exhaust valve by running without an exhaust gasket. | |
| May 21, 2011 | 16,318 | Released camchain adjuster | Ian Johnston | $0 | Making sure this isn't the cause of some clattering in the engine (no change -- it's most likely the starter clutch making the noise) | |
| May 21, 2011 | 16,412 | Replaced carburetor main jets | Ian Johnston | $0 | The bike was running weak with #95s, and frequently died at idle, to be revived by choke. Increased jets to #98 size. | |
| May 21, 2011 | 16,512 | Lubricated and adjusted drive chain | Ian Johnston | $0 | Chain required .75 turns of adjustment. | |
| August 24, 2011 | 16,563 | Added ~150ml engine oil | Ian Johnston | $0 | none | |
| August 24, 2011 | 16,563 | Adjusted front brake shoe engagement timing | Ian Johnston | $0 | none | |
| August 28, 2011 | 16,611 | Adjusted mixture settings | Ian Johnston | $0 | Now using #100 main jets. 100 vs 102 was no perceptible difference; aiming a bit lean as it's hot today, and this should result in an acceptable mixture in cooler weather too. Also dropped needles one notch, and adjusted idle mixture. | |
| August 28, 2011 | 16,611 | Replaced sparkplugs | Ian Johnston | $0 | Old plugs were fouled due to excessively rich idle mixture. Replaced with NGK B8HS plugs. | |
| August 28, 2011 | 16,611 | Adjusted spark timing | Ian Johnston | $0 | Advanced timing slightly, looking for a bit more power at the top end. | |
| October 25, 2011 | 16,734 | Added ~200 ml engine oil | Ian Johnston | $0 | ||
| 2012 | ||||||
| January 8, 2012 | 16,810 | Topped up battery elecrolyte | Ian Johnston | $0 | Electrolyte was very low, doubtless accounting for many of the recent electrical gremlins. | |
| August 19, 2012 | 16,910 | Replaced alternator stator | Ian Johnston | $0 | Original stator had lost one of three coil wires. Replacement came from a spare engine. Noticed that two of six "fingers" behind the rotor had broken off and were sitting in the bottom of the case, which must have occurred since the last rebuild. No apparent effect to engine. | |
| August 19, 2012 | 16,910 | Replaced engine oil | Ian Johnston | $8 | Also cleaned out the oil spinner, which had a very moderate build-up of crud. Used Delo 400 15W50. | |
| 2013 | ||||||
| Date | Mileage | Service | Mechanic/Shop | Price | Notes | |
| February 15, 2013 | 17,123 | Lubricated drive chain | Ian Johnston | $0 | Didn't explicitly check tension, but it felt correct. | |
| June 26, 2013 | 17,291 | Lubricated and tensioned drive chain | Ian Johnston | $0 | Required 1.25 turns adjustment. | |
| October 19, 2013 | 17,316 | Replaced ignition coil | Ian Johnston | $120 | Used Accel Super Coil | |
| October 19, 2013 | 17,316 | Replaced fuel lines | Ian Johnston | $5 | ||
Created by Ian Johnston. Questions? Please mail me at reaper at obairlann dot net.