Service Log

I'm keeping a log of all the service that I'm having done or doing to this motorcycle, and I figured I could keep it online just as easily. I have no idea if this will be helpful to anyone other than myself.

2003
Date Mileage Service Mechanic/Location Price Notes
June 16, 2003 9091 Pre-purchase inspection, spark plug installation, chain adjustment and lubrication Seattle Cycle Center $135.33 Inspection found good compression (190 psi in each cylinder), brake pads at 50%, tires at 40%, coolant good, oil OK, tires a bit underinflated, chain/sprockets good and spark plugs in good condition (although they were replaced during the inspection). Chain was quite loose, and the tech adjusted and lubed it as long the bike was there. Service was $120 (2 hours of shop time), and spark plugs were $2.19 each plus tax.
June 22, 2003 9240 Engine oil and filter change Ian Johnston about $10 Previous owner had the drain bolt and filter bolt in way too tight. Using CarQuest CFI-89941 filter (~$6) and Castrol 20W50 (~$2 per quart). Old oil was very light weight, probably too light for more than 40° F. Did not replace drain bolt crush washer (forgot to get one), no leaks evident yet.
June 26, 2003 9268 Replaced both tires and front/rear brake pads Ian Johnston and Seattle Cycle Center tires: $255, brake pads: $60 Tires mounted to wheels by SCC, all other work done by me. Tires mounted are Bridgestone BT45s, 100/90-16 front and 130/90-16 rear. Brake pads are now EBC blacks (organic, non-sintered).
July 8, 2003 9390 Adjusted valves, changed coolant, installed fuel filter Ian Johnston liquid gasket: $8, coolant: $18, fuel filter: $3, special valve adjustment tool: $40 Much pain involved in this operation. I'm debating never doing it again and just having a mechanic do it. Couldn't even get to the vacuum points to adjust carb sync. Used "Engine Ice" coolant, since it's biodegradable and claims to be less toxic.
July 15, 2003 9544 Adjusted carburetor balance Ian Johnston $0 none
August 2, 2003 9903 Lubricated and adjusted drive chain Ian Johnston $0 No adjustment actually needed. Chain lube was about $8 for a big can that will last me for years, so I'm listing the lubrication as having no cost. Actual cost is probably around 3-5 cents per lube.
September 3, 2003 10,505 Lubricated and adjusted drive chain Ian Johnston $0 Slight adjustment needed -- perhaps 1/4 turn of adjusting bolts to take up slack
September 5, 2003 10,532 Replaced headlight bulb Ian Johnston $15.22 None
September 18, 2003 10,881 Replaced rear shock with one from an "'86 Ninja 500" Ian Johnston $32.29 Purchased from Ebay, the bottoming bumper looks marginal. Greater improvement may be achieved by finding a newer model of shock. Ride height is dramatically improved.
September 29, 2003 11,172 Lubricated and adjusted drive chain Ian Johnston $0 No adjustment needed
October 21, 2003 11,551 Lubricated and adjusted drive chain Ian Johnston $0 Lubed after particularly heavy rain, no adjustment needed
December 1, 2003 12,018 Lubricated and adjusted drive chain Ian Johnston $0 Needed about 1/2 turn of adjustment (~3mm too much slack)
December 21, 2003 12,213 Changed engine oil and filter Ian Johnston $13.57 Used Mobil 1 10W30 full-synth and CarQuest filter
2004
Date Mileage Service Mechanic/Location Price Notes
January 10, 2004 12,254 Lubed chain Ian Johnston $0 Lubed and cleaned chain after washing the bike (coated in grit, post-snow). No adjustment.
January 11, 2004 12,265 Installed RaceTech .75 kg/mm fork springs Ian Johnston $110 Used 5 1/16" spacers for "standard" preload.
February 29, 2004 12,833 Lubricated and adjusted drive chain Ian Johnston $0 Adjusted to remove ~2mm too much slack
March 30, 2004 13,285 Replaced stock horn with Fiamm "Freeway Klaxons" Ian Johnston $32.64 Used both high and low tone horns.
March 31, 2004 13,307 Removed "high" Fiamm horn Ian Johnston $0 Having both horns installed causes interference with the front fender going over sharp bumps.
April 4, 2004 13,315 Lubed and adjusted chain Ian Johnston $0 Required some adjustment to take up slack.
April 8, 2004 13,355 Topped up engine oil Ian Johnston $0 Took ~200ml
April 11, 2004 13,631 Lubed chain Ian Johnston $0 None
April 12, 2004 13,631 Topped up engine oil Ian Johnston $0 Took ~200ml.
May 5, 2004 14,074 Topped up engine oil Ian Johnston $0 Took ~300ml. Clutch and gears were starting to act like there wasn't enough oil, even though the oil was 3/4 up the sightglass. I'm not that impressed with synth oil so far.
May 5, 2004 14,178 Lubed and adjusted drive chain Ian Johnston $0 Chain required 1 and 1/4 turns(!) adjustment after just over 800 miles since the last time. Time for a new chain soon, since I now suspect that this chain's 7000+ miles of no maintenance from the previous owner is catching up to it. The chain also has numerous red spots which appear to be rust.
May 9, 2004 14,229 Replaced front brake pads and inspected rear pads Ian Johnston $32.27 Front pads got down to less than 1mm clearance -- one pad was down to metal, the other was around .5mm. Cleaned the caliper as well. Rear pads were at ~3.5mm.
May 29, 2004 14,372 Replaced drive chain and sprockets Ian Johnston ~$180 Used RK 520XSO chain with rivet-type master link, and SunStar standard-gearing hardened steel sprockets.
June 1, 2004 14,504 Replaced front and rear brake lines with stainless steel Galfer lines Ian Johnston $103 ($55 front, $40 rear, $8 shipping) A short ride suggests that brake feel and responsiveness is greatly improved. Front brakes are now significantly stronger-feeling. Purchased from cyclebrakes.com
June 5, 2004 14,516 Replaced rear wheel cush drive damper Ian Johnston $44 None
June 8, 2004 14,516 Replaced banjo bolts on new brake lines (previously overtorqued); replaced brake fluid from a very fresh bottle Ian Johnston $6.47 Only cost was for another bottle of brake fluid. Replacement bolts were free from Galfer after I explained that I overtorqued the first set. Braking power is quite impressive now.
June 28, 2004 14,879 Lubricated drive chain Ian Johnston $0 No adjustment needed
July 6, 2004 14,989 Lubricated clutch cable Ian Johnston $0 None
July 14, 2004 15,131 Topped up engine oil Ian Johnston $0 Added ~250 ml
July 18, 2004 15,185 Installed driving/fog light set Ian Johnston ~$75 See the project page. Price reflects half acquisition cost, since the other lights will be going on the Le Mans.
July 18, 2004 15,262 Replaced engine oil and filter Ian Johnston ~$12 Used Castrol Syntec 5W50 full-synth and a CarQuest filter element. Previous 10W30 was like water coming out of the engine -- clearly too thin. Purchase new crush washers before next oil change.
July 27, 2004 15,405 Lubricated drive chain Ian Johnston $0 No adjustment needed
August 4, 2004 16,094 Lubricated drive chain Ian Johnston $0 No adjustment needed
August 22, 2004 16,291 Adjusted valves; replaced valve cover gasket Ian Johnston $30 Valves were definitely out of adjustment in various directions. This time was much easier because I took off all the stuff I should have taken off last time, too.
August 22, 2004 16,291 Cleaned and gapped sparkplugs Ian Johnston $0 I was unable to locate new sparkplugs, or I would have just replaced them.
August 22, 2004 16,291 Replaced engine coolant Ian Johnston $17 Used Engine Ice again. Works fine, and I'm fond of the idea of it being less toxic.
August 22, 2004 16,307 Synchronized carburetors Ian Johnston $0 Minor adjustment required.
August 22, 2004 16,307 Replaced rear turnsignal bulbs; added drain-hole to right rear signal housing Ian Johnston $2.50 Right rear turnsignal had been collecting water and grit. Cleaned out ~3ccs of accumulated sand from inside the housing. Hopefully the drain holes will prevent it from building up again. I can't tell where the water and sand are entering.
August 23, 2004 16,320 Replaced spark plugs Ian Johnston $5 None
August 27, 2004 16,414 Lubricated drive chain Ian Johnston $0 None
September 18, 2004 16,792 Replaced rear tire with new 130/90-16 Bridgestone BT45 Ian Johnston $130 New tire tread depth is ~7mm. Previous tire (~3mm tread depth in center) was holed by miniscule nail.
September 19, 2004 16,855 Lubricated drive chain Ian Johnston $0 None
September 22, 2004 16,911 Added ~200 ml engine oil Ian Johnston $0 None
October 5, 2004 17,297 Added ~250 ml engine oil Ian Johnston $0 None
October 5, 2004 17,311 Lubricated and adjusted drive chain Ian Johnston $0 Chain required 1/2 turn tightening.
October 17, 2004 17,489 Added ~300 ml engine oil Ian Johnston $0 None
November 5, 2004 17,787 Lubricated and adjusted drive chain Ian Johnston $0 Chain required 1/2 turn tightening.
November 21, 2004 18,057 Added ~200 ml engine oil Ian Johnston $0 None
December 12, 2004 18,227 Lubricated and adjusted drive chain Ian Johnston $0 Required 1 full turn adjustment to take up slack
December 16, 2004 18,335 Replaced front tire with new BT45 100/90-16 Ian Johnston ~$105 Some trouble getting speedo drive aligned properly -- ensure antirotation tabs are aligned with fork tabs next time
December 16, 2004 18,335 Replaced front brake pads, inspected rear pads Ian Johnston $28.43 Front pads were at ~1mm (after just 4000 miles!), rear pads at ~3mm
2005
Date Mileage Service Mechanic/Location Price Notes
January 12, 2005 18,712 Lubricated and adjusted drive chain Ian Johnston $0 Required 1.5 turns of adjustment to take up slack
January 16, 2005 18,739 Added ~250 ml engine oil Ian Johnston $0 None
January 21, 2005 18,786 Lubricated choke and throttle cables Ian Johnston $0 None
February 2, 2005 18,883 Replaced left switchpod with 2000 ZX12 switchpod Ian Johnston $18.50 New switchpod acquired via Ebay. This allows hazard blinkers.
February 2, 2005 18,883 Cleaned and lubricated engine air filter Ian Johnston $14.50 Cost represents purchase of a K&N cleaning and oiling kit which will be used at least 30 times.
February 10, 2005 18,986 Added ~100 ml engine oil Ian Johnston $0 None
February 23, 2005 19,163 Lubricated and adjusted drive chain Ian Johnston $0 Required 1.25 turns of adjustment to take up slack
February 23, 2005 19,205 Lubricated drive chain Ian Johnston $0 Lubricating after washing the bike
March 4, 2005 19,389 Replaced engine oil and filter Ian Johnston ~$17 Used Castrol Syntec 5W50 oil and CarQuest CFI-89941 filter
March 10, 2005 19,483 Replaced clutch springs Ian Johnston ~$30 ($10 springs, $15 new gasket, $5 oil) Used EBC clutch springs. Clutch cover had to be scraped to get old gasket off, check for oil leaks and weeps. Refilled about 500ml engine oil to replace spilled oil from cover removal.
March 25, 2005 19,733 Lubed and adjusted drive chain Ian Johnston $0 Chain required 2 turns of adjustment. sigh
April 7, 2005 19,863 Added ~150 ml engine oil Ian Johnston $0 None
April 27, 2005 20,152 Added ~200 ml engine oil Ian Johnston $0 None
April 30, 2005 20,189 Lubricated and adjusted drive chain Ian Johnston $0 Required 1.25 turns of tightening.
May 22, 2005 20,758 Lubricated and adjusted drive chain Ian Johnston $0 Required 1.5 turns of tightening.
June 3, 2005 21,073 Added ~400 ml engine oil Ian Johnston $5 Used Mobil 1 15W50
June 9, 2005 21,221 Replaced license plate bulb Ian Johnston $3 None
June 12, 2005 21,247 Replaced front fork oil Ian Johnston $6 None
June 20, 2005 21,277 Lubricated and adjusted drive chain Ian Johnston $0 Chain required 2 full turns adjustment
June 20, 2005 21,277 Replaced front brake rotor Ian Johnston $160 Used Galfer round rotor from cyclebrakes.com. It was purchased on close-out since they're discontinuing the model.
June 20, 2005 21,277 Replaced front brake pads Ian Johnston $20 Discounted since they were purchased with the above rotor.
July 12, 2005 21,594 Sanded front brake rotor Ian Johnston $0 Trying to reduce glazing on the rotor surface.
July 22, 2005 21,643 Added ~200ml engine oil Ian Johnston $0 none
July 27, 2005 21,712 Adjusted valves Ian Johnston $0 7 of 8 valves were too tight. Much easier this time, removing all parts that might be in the way.
July 27, 2005 21,712 Replaced engine coolant Ian Johnston $20 none
July 27, 2005 21,712 Replaced spark plugs Ian Johnston $6 Old plugs looked alright, but it made sense to replace them now.
July 27, 2005 21,712 Removed steering head bearings Ian Johnston $0 Old bearing races are notched. Replacement bearings ordered.
August 4, 2005 21,712 Installed new steering head bearings Ian Johnston $35 These tapered roller races are never coming out again.
August 4, 2005 21,712 Cleaned and re-oiled air filter element Ian Johnston $0 none
August 14, 2005 21,945 Lubricated and adjusted drive chain Ian Johnston $0 Chain needed 1.75 turns adjustment
August 31, 2005 22,163 Added ~200 ml engine oil Ian Johnston $0 none
September 3, 2005 22,230 Replaced final drive chain Ian Johnston $150 Used RK 520XSO chain and SunStar front sprocket. Reused stock rear sprocket, since it looked decent.


Back to the motorcycle page

Created by Ian Johnston. Questions? Please mail me at reaper at obairlann dot net.