EPIC SERVICE DAY!
* = to be done later.
To buy:
GLOVES
Silicone
Electrical contact cleaner
Heatshrink 70mm
Engine oil
Choke cable (?)
Heat proof Paint
*Grips
*Mirrors
Brake Fluid
Radiator fluid (1 litre fluid / 1 litre distilled water)
Distilled water
Things to fix:
-Change oil
-Change radiator fluid
-Change brake fluid
-Bleed brakes
-Change air cut valve on pesky RH carb.
-Valve clearances
-Carb Float levels
-Clean carbs while off
-Silicone the airbox
-Silicone the air intakes
-Heat shrink the air intakes
-Heat shrink the coil cables (too flimsy)
-Paint radiator shroud
-Paint & treat rusted parts
Clutch shudder (?)
Clunking drive shaft (?)
Things to install:
-New coils
-New ACV
*New grips
*New mirrors
-Brake master
-New front engine cover & gaskets
-New oil filter & gaskets
-Piece of brass to spark plug caps
-New choke cable / relocate choke cable to tab (?)
Process:
ONGOING: Clean surfaces as needed with degreaser. Replace gloves as needed.
PREP TIME
Apply Coffee to mouth and Gloves to hands.
1. Drain oil
2. Drain radiator
3. Take seat off
4. Take tank off
5. Take radiator shroud off
6. Prep & paint radiator shroud
7. Prep & paint rusted bits and bobs
8. Drain carbs
9. Take carbs off
10. Take air intakes off
a) Put cloth rag plug into air intake on engine.
11. Take lid off airbox
12. Silicone the airbox lid & boots & reinstall lid.
13. Silicone & Heatshrink air intakes
14. Change air intake gasket rubbers
15. Blast carbs with cleaner and air compressor (Refer to http://www.pdsrecording.site90.com/cxgl500/Carbs2.htm)
a) Take a photo of what jets go where
b) Take jets out and softly clean
c) 1 carb at a time.
d) Little bit of WD40 when putting back together
e) Install new Air Cut Valve
16. Take carbs bowls off and check float height
17. Fix choke cable or install new one.
BREAK TIME (Apply new coat to radiator shroud, Check air intake silicone)
Re-Apply Coffee.
18. Take off coils
19. Clean coil terminals
20. Install new coils to the back bracket
21. Make a bracket for the front portion.
22. Heatshrink the new coil wires
23. Take out fuse/resistor in caps and install brass pieces
24. Measure twice then cut coil wire to size and install caps
25. Take off rocker covers
26. Check valve clearances & Adjust as needed (Refer to http://www.pdsrecording.site90.com/cxgl500/CXGLTappets.htm#CXGLTappets)
27. Put rockers covers back on.
28. Install plug caps.
BREAK TIME (Check shroud, apply paint if needed, check air intake silicone)
Re-Apply Coffee and Food.
29. Take radiator off (Refer to MANUAL)
30. Take front engine cover off.
31. Inspect clutch basket for grooves.
32. Adjust drive chain tension (Refer to MANUAL)
33. Replace all gaskets and O-rings (Refer to MANUAL)
34. Install new cover.
a. Ensure oil pressure cable is reconnected
b. Leave crank bolt cover exposed for later.
35. Take off oil filter cover & clutch cover.
36. Install new oil filter & new gaskets for both
37. Install covers, Fill up with oil and check for leaks.
38. Install clutch cable.
39. Flush radiator with garden hose.
40. Clean radiator with soapy water
41. Blast with compressed air.
42. Check radiator shroud and fan for cracks/silly buggers.
43. Rotate engine with crank bolt (used in tappets adjust) to see if fan is clipping shroud.
44. Install crank bolt cover.
45. Install radiator.
46. Fill with 50/50 mix of coolant. (Bleed system later)
BREAK TIME
If afternoon, apply beer.
47. Drain brake fluid.
48. Remove master brake cylinder.
49. Apply some brake fluid to new master cylinder and check reservoir for leaks.
50. Install new master cylinder & Fill up.
51. Bleed brakes (Refer to MANUAL)
52. Clean all surfaces with brake cleaner.
53. Check operation. Rebleed if needed.
54. Install air intakes.
55. Install carbs.
56. Check smooth operation.
57. Install radiator shroud.
58. Install tank.
59. Cross fingers & See if it start. If not, throw a spanner somewhere and check engine over.
60. Bleed cooling system if running.