Here are some of the maintenance methods we've received from the Webike Community "MOTO HACK Maintenance" campaign that we'd like to refer to. Maybe you have an idea that you'd like to try!
In this article, I'm going to introduce the maintenance HACK from M.Nori who ride ZEPHYR750.
Motorcycle introduction and its maintenance
About the vehicle
1991 Zephyr 750 I got this motorcycle from my former teacher in Okinawa. There are many parts to replace for an old motorcycle that is 29 years old, and I ride it every day, scared that the engine will not stop in the middle of touring.
Working process
The choke lever, which is used to start the engine, cannot be fixed and returns to its original position.!
Working hours
40 minutes
Working difficulty
It's easy to make your own parts
Items to use
In the end, I made a part from a scrap of cutting board that I bought at 100 uniform, and fixed the choke lever!
Learn more about the work
Overall flow
1. Check the condition of the left handle switch and exterior.
2. Loosen the clasp on the lever securing the handlebar. Remove the mirror as it is in the way.
3. Remove the two screws on the back and carefully separate them.
4. Check the condition of the interior, rust, broken plastic parts, etc.
5. Check the plastic parts that hold the choke lever in place.
6. Cleaning the interior and removing rust from the springs.
7. Created new plastic parts that had been damaged.
8. Capable of removing springs from plastic parts.
9. Temporarily fastened to the place where it was installed.
10. Check the operation of the choke lever by temporarily fastening it to the steering wheel.
11. If not, adjust the angle of the surface of the plastic parts.
12. Repeat the above and finally maintighten and put it back on.
Details of the work
I cleaned the interior with a used toothbrush while checking the switches and wiring for corrosion. The body side was fine, just a little dirty.
Take out the plastic part with the red circle in the cover photo and check it out. The parts that were damaged this time were in pieces and the original shape was unknown. The internal spring had developed rust. The choke lever will not stop at this point.
I made it with a little hard sponge to try it out. It's easy to process, so I made it the same shape and built it in, but it's softer than I thought it would be, so I couldn't fix the lever.
This time, I reused a white cutting board that was left over from when I replaced it with a new one. Soft and easy to cut and process with a saw. It's 100 percent uniform, so it's easy on the wallet. You can try it out with any material you have on hand that is reasonably firm and soft.
Cut out and process like this. I shaved off the part that was hit while installing it. The size is a little bit bigger, so it can be adjusted while grinding.
This is the shape I tried. Drill a hole on the bottom surface for the spring. How about making the parts longer without the spring? When I made it to try it out, the lever stopped due to wear with no problem. However, in the long term, it deteriorated and the symptoms of not being able to fix the lever would recur. The spring force moves the part up and down to adjust the lever friction, so if you want to use it for a long time, I made it like the original part.
Install the switch to the handlebar after assembling it temporarily.
Install the choke lever with the wire. Adjusting friction and checking operation.
Choke lever friction is back.
- The lever was fixed.
- Pulling the choke from the red line to the orange line did not return the lever.
Every time I had to start the engine with my hand on the choke lever so I could get my hands off the choke lever. It's a little bit easier.
Points of caution and tips for work, etc.
If you concentrate on the work, the parts will be lost quickly, so store them in a tray or other container. Use a positive screwdriver that fits the positive screw. Screws are often stuck together and crush the screw heads right away. If the clear plastic parts inside disintegrate and you can't find the original model, give up and search for the shape online!
The plastic parts created when you put them back on the handle during the work in 10. Be careful not to force the cover to fit together, as it may damage the threads and head!
*Lubricate the choke cable because the handlebar was disassembled.
Advice
- Only plastic parts are not for sale. *Only left-handed switch assembly is for sale.
- The material is not rubber, sponge, and not hard enough.
- The choke lever cannot be fixed by slipping due to deterioration of the plastic parts, so increase the friction to stop the lever.
- Do not lose the choke lever because it is adjusted by the internal spring tension.
Thank you M.Nori, for posting this valuable maintenance HACK! You will receive 1,500 points to spend at Webike!
The articles on MOTO HACK are composed and reprinted from user contributions. The effects and methods described are at the discretion of the user, and Webike is not responsible for any problems that may occur.
