New bike prep

SpeedyManiac

SpeedyManiac

New member
Hey guys,
I got a new bike (09 EC250 Racing, sold the 07) and am getting it set up for the season. I've made a list of things to do, and have a couple questions. Also, I still feel like I'm forgetting something. If you can think of anything let me know.

Here's the list of things done so far:
-removed signal lights and horn
-lock tite/anti seize all bolts (especially triple clamp pinch bolts)
-fill axles, swingarm pivot and steering head shaft with silicon to prevent corrosion/filling with dirt
-install skid plate and rad guards
-install steering damper, flexx bars, bark busters,
-bike is currently away getting a custom pipe cage built

Here's the list of things that will be done when I get the bike back:
-grease linkage, swingarm and steering head bearings
-grease rear brake pedal and kickstart pivots
-install grease fittings on linkage, swingarm, rear brake pedal and kickstarter (should I? I had them on my 01 EC200 and didn't have them on my 07 EC250. Will I damage the seals?)
-flip footpeg pins
-jetting?!? Does the JD jetting kit work for the new short body carb?
-remove dual sport switch and install regular kill switch and headlight switch
-change oil
-change coolant
-put on some real tires with mousses in them

So, anyone know if the JD jetting kit works on the new short body carb? Also, see anything I'm forgetting before I go get this bike dirty?
 
as far as grease zerks on the linkage ... I don't really know but ... on my drz anything with a zerk had a groove machined in it. this was I assume to allow a passage for grease to get all the way around the bearing. I don't believe any such groove would be in the any of the gasser linkage. This would make me wonder how well the grease would move around. I know that on some of the linkage there is a space between the roller bearings. If you inject grease into that area is there enough slop for the grease to penetrate the bearings?? Or is it too tight and it will just pack the gap?? I have done the linkage and swing arm on my 06 several times and find that the o rings seem to do a very good job at keeping things clean. last year was very wet and muddy and when i pulled the linkage off, the grease in that gap between the roller bearing was pefectly clean. Zerks probably wouldn't hurt but I keep an eye on things and make sure the grease was getting all the way around the bearing. My husky has zerks onthe linkage. My drz had them on the swing arm and linkage
 
The gasser has from the factory excellent coverage of grease on the susp linkages, headstem and rear brake i checked my gasser 450 08 from new and it was a wasted of my time, after 18months i did the full strip down and the only area that required to be greased was the head stem, even the linkages where ok, but i still cleaned them.i had 8000kms on the clock, Unless you like regreasing those parts you can leave then until the season is over and you will have no problems IMO.
 
Hey Steve,

Sounds like your got things under control. If you get a chance post up some pics of your new guard please.
 
If you really want to overdo it, you can pull the wheel bearings, peel off the seals and fill the bearings with grease (be sure to reinstall the seals).

I was amazed the first time i did this how little grease is in new sealed bearings.

Even if you don't do it now, be sure to do it when you replace those bearings in the future.
 
bondo said:
If you really want to overdo it, you can pull the wheel bearings, peel off the seals and fill the bearings with grease (be sure to reinstall the seals).

I was amazed the first time i did this how little grease is in new sealed bearings.

Even if you don't do it now, be sure to do it when you replace those bearings in the future.
Click to expand...

I did this. Probably at your prompting.
 
bondo said:
If you really want to overdo it, you can pull the wheel bearings, peel off the seals and fill the bearings with grease (be sure to reinstall the seals).

I was amazed the first time i did this how little grease is in new sealed bearings.

Even if you don't do it now, be sure to do it when you replace those bearings in the future.
Click to expand...

i do this on all bearings. only takes a few seconds to properly pack bearings. rarely have i opened one up and it's actualy greased...
 
Steve,

You are missing a few items:
- Modify the kickstand pivot (with a master link) or just remove kickstand.
- Route the 2 upper carb vent hoses up into airbox.
- Route the right side PV hose up over the radiator mount and back down.
- Check that the left side PV hose is free to drain (not zip-tied shut).
- Swap the OE rim locks for some Motion Pro rim locks.

Congrats on the new bike!
 
Thanks for reminding me about vent hose routing Matt. As for the kickstand, I've learned to like the auto retract feature as it keeps people from touching my bike. I'll use the OEM rim locks since I run mousses and they actually work pretty good for that.

I'll post some photos of the bike when it's ready to ride.

Steve
 
The two upper hoses off your carb go into the airbox or...

I took my T6 Carburetor Filter I purchased from 7602 Racing off my Husky 125 and put it on my EC.

All hoses go down except the middle one heads up high under the gas tank.

CarbHoses.jpg
 
Forget the zerks, good grease and the OEM orings are great. The old bikes had looser fitting seals.

Get stainless wheel spacers made. They won't groove and do more for protecting bearings than anything else.
 
SpeedyManiac said:
Hey guys,
I got a new bike (09 EC250 Racing, sold the 07) and am getting it set up for the season. I've made a list of things to do, and have a couple questions. Also, I still feel like I'm forgetting something. If you can think of anything let me know.

Here's the list of things done so far:
-removed signal lights and horn
-lock tite/anti seize all bolts (especially triple clamp pinch bolts)
-fill axles, swingarm pivot and steering head shaft with silicon to prevent corrosion/filling with dirt
-install skid plate and rad guards
-install steering damper, flexx bars, bark busters,
-bike is currently away getting a custom pipe cage built

Here's the list of things that will be done when I get the bike back:
-grease linkage, swingarm and steering head bearings
-grease rear brake pedal and kickstart pivots
-install grease fittings on linkage, swingarm, rear brake pedal and kickstarter (should I? I had them on my 01 EC200 and didn't have them on my 07 EC250. Will I damage the seals?)
-flip footpeg pins
-jetting?!? Does the JD jetting kit work for the new short body carb?
-remove dual sport switch and install regular kill switch and headlight switch
-change oil
-change coolant
-put on some real tires with mousses in them

So, anyone know if the JD jetting kit works on the new short body carb? Also, see anything I'm forgetting before I go get this bike dirty?
Click to expand...

Well done,If you don't mind I'm going to hijack your list for mine when it turns up.
What are your thoughts on new bike run in?
 
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