2 lessons learned!

[Marshall G]

I set out to install my horn, put my new GUTZ tall seat on and change the gearbox oil. I rode my EX around a bit to 'warm it up' and I drained the gearbox oil as per the instructions. I captured it and measured it. LESS THAN 60CCs! No leaks (no issues thankfully) but spec calls for 120CCs. Bike has 300 miles on it. Lesson one - even if you're not due for a change, check the level! Mine was apparently only half full from the factory.

Lesson two. Last time I took the shroud/seat assembly off (to install hillbilly Steg Pegz) I apparently overtightened a couple of the front shroud bolts. With the shoulder on the bolts, they kind of smack down/lock down on the brass little boss/nut receivers. When I went to remove them again, the brass inserts are just kinda pressed into plastic cavities in the shrouds and they're not very tough. Several of them spun while trying to remove the assembly and I had to butcher part of the shroud assemble and also the inner plastic tank cover thing. It took me forever to fight that out as you can't get a bite on the brass slug to hold it! So, lesson number two - don't overtighten any of those shroud bolts.

 

[Philip]

So, lesson number two - don't overtighten any of those shroud bolts.

Use blue Loctite and tighten them looser.

 

[Brokein2]

Where did you see 120? When you use the level screw the bike only ends up holding about 60cc just like you saw.

 

[Marshall G]

I thought I saw it on the Stark video, but now I can't recall. I did it by the book - until it drained out the level hole - but I thought it was 120 CCs.
Now I'll have to search where I saw that.

 

[arkngl]

I thought I saw it on the Stark video, but now I can't recall. I did it by the book - until it drained out the level hole - but I thought it was 120 CCs.
Now I'll have to search where I saw that.

SAM says 80ml. Not 60 or even 120. I use a liqui moly additive with synthetic oil 70w90 that reduces the sound.
SAM is my best friend.
See ya

 

[Chaconne]

Using the level hole is better than documentation which can contain errors or be wrong. Oh and BTW SAM uses what is in the documentation and will mime an error since he is a mime and everyone knows mimes make lousy service techs...

 

[Marshall G]

Sounds good. Thanks.

mg

 

[wfopete]

SAM = Garbage in, garbage out.

 

[Chaconne]

SAM = Garbage in, garbage out.

In CS we call it glorified Stack Overflow...

 

[kailua808]

I set out to install my horn, put my new GUTZ tall seat on and change the gearbox oil. I rode my EX around a bit to 'warm it up' and I drained the gearbox oil as per the instructions. I captured it and measured it. LESS THAN 60CCs! No leaks (no issues thankfully) but spec calls for 120CCs. Bike has 300 miles on it. Lesson one - even if you're not due for a change, check the level! Mine was apparently only half full from the factory.

Lesson two. Last time I took the shroud/seat assembly off (to install hillbilly Steg Pegz) I apparently overtightened a couple of the front shroud bolts. With the shoulder on the bolts, they kind of smack down/lock down on the brass little boss/nut receivers. When I went to remove them again, the brass inserts are just kinda pressed into plastic cavities in the shrouds and they're not very tough. Several of them spun while trying to remove the assembly and I had to butcher part of the shroud assemble and also the inner plastic tank cover thing. It took me forever to fight that out as you can't get a bite on the brass slug to hold it! So, lesson number two - don't overtighten any of those shroud bolts.

Same issue with the shroud bolts. All four spin so I cannot back them out. I didn’t think I tightened them much so make sure you barely tighten them. I’m not looking forward to cutting up the plastics to remove them.

 

[wfopete]

I only had one spin. Drilled the head of the bolt off and was able to remove the rest by clamping the plastic surrounding the insert.