Author Topic: First Service Done  (Read 2759 times)

MJR

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First Service Done
« on: June 09, 2016, 06:47:56 PM »
Racked up 600.9 miles. Just completed the first service, oil and filter change (service manual specs 2.6L/2.75qts or about 3 quarts with filter), remove/clean/reinstall oil strainer, and rear diff oil (320 ml) change. After servicing it Tuesday night I went out and bought a couple of other tools last night. I've also done a few adjustments since I took delivery of the bike such as throttle cable play, rear fender fit, and front right side lens fit (normally turn signal lens but not in the US has no LEDs). Still need to do something about the chrome screw the dealer put in the handle bar cover.

The tools required are minimal, a 3/8" torque wrench, a 3/8" ratchet (I like my long handle flex head one), a 17mm socket, oil filter wrench (space is tight so I went and bought a rubber strap one though a metal strap one of the right size would be best), a funnel (used my transmission one but later went and bought one with a hose which I need to replace the hose with a reinforced one soon), and something to measure the diff oil since there's no level plug or dipstick. I did remove the engine skid plate though it's not required I wanted to have a look and I think it kept me from dripping oil on it.

Original engine oil was 5W50 which covers a huge temperature range but I switched it to 15W40 Rotella T like I run in my Burgmans and the rear diff oil was 90wt (like my Burgmans also) which I switched to 85W90 Valvoline synthetic. Torque specs for the oil strainer cover per FSM are 1~2 kgf•m (7-14 ft.lb converted, I did about 10.5 ft.lb), oil drain plugs in the engine and rear diff specs are 2~3 kgf•m (14-21 ft.lb coverted, I did about 18 ft.lb). Funny the FSM doesn't mention or point out the engine crankcase oil drain plug and there is a magnet on it that should be cleaned. Oh and the $18 OEM Kymco oil filter part # 1541A-LBA2-E00 is actually a HiFlo HF147 that can be had from Chaparral Motorsports for $6, lol. Another weird thing is the oil drain plugs for both the engine and diff have aluminum crush washers on them but according to the parts catalog are only sold with the drain plugs themselves. I'll just keep reusing them as I have on my other bikes. Some photos.

My new oil funnel and strap wrench.


HiFlo HF147 and OE Kymco 1541A-LBA2-E00 which is a reboxed HiFlo HF 147.


Bottom view with engine skid removed showing oil filter, oil strainer cap, and engine oil drain plug.


Shows how little space there is for regular oil filter wrenches. I think a proper size metal strap one would be perfect, need to get one as I think the rubber one I just got may be a little thick.


Oil screen removed.


Oil screen debris.


Clean screen.


Oil drain plug magnet needs to be cleaned.
« Last Edit: June 09, 2016, 07:51:51 PM by MJR »
'03 Clipper Yellow Honda Reflex
'03 Coast Cyan Atlantic 500
'14 White MyRoad 700i
'09 Mirage White Burgman 650
'06 Oort Gray Burgman 650 project
'05 Sonic Silver Burgman 650 project
'03 Space Blue Burgman 650, rebuilt/upgraded CVT w/Polish adapter
'03 Space Blue Burgman 650 parts bike

MJR

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Re: First Service Done
« Reply #1 on: June 09, 2016, 06:51:58 PM »
Here's the rear diff photos.

Draining the gear oil.


Measured amount of new gear oil.


Fill plug back in after putting the drain plug back and refilling with oil.
'03 Clipper Yellow Honda Reflex
'03 Coast Cyan Atlantic 500
'14 White MyRoad 700i
'09 Mirage White Burgman 650
'06 Oort Gray Burgman 650 project
'05 Sonic Silver Burgman 650 project
'03 Space Blue Burgman 650, rebuilt/upgraded CVT w/Polish adapter
'03 Space Blue Burgman 650 parts bike

CROSSBOLT

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Re: First Service Done
« Reply #2 on: June 09, 2016, 09:34:52 PM »
Nice pictures! Good write-up! That spin-on is pretty tight especially next to the oil cooler.

Karl
Karl

Three motorcycles 1960-1977 (restored a 1955 BSA)
Agility 50
Yager 200i
Downtown 300i
Navy tech, Ships Engineer, pilot and aircraft mechanic

pipster326

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Re: First Service Done
« Reply #3 on: June 13, 2016, 03:46:21 PM »
You would be correct, downtown 300i


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pipster326

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Re: First Service Done
« Reply #4 on: June 13, 2016, 06:32:00 PM »
Sorry for the mis-post , still trying to figure out some stuff on the forum.



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MJR

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Re: First Service Done
« Reply #5 on: June 14, 2016, 12:10:17 AM »
Nice pictures! Good write-up! That spin-on is pretty tight especially next to the oil cooler.

Thanks, not too bad with my smart phone. Very tight, good thing I didn't try my claw tool as that would have torn up the cooler. The rubber strap wrench would work but you had to kinda squeeze it in there so I ended up ordering a GearWrench/KD Tools 3324D/3324 metal oil filter strap wrench which should do the trick. It fits filters from 2 1/2" to 3" (64mm to 76mm). The filter measures 67mm on the can and about 70mm where it's crimped together.

« Last Edit: June 14, 2016, 12:12:06 AM by MJR »
'03 Clipper Yellow Honda Reflex
'03 Coast Cyan Atlantic 500
'14 White MyRoad 700i
'09 Mirage White Burgman 650
'06 Oort Gray Burgman 650 project
'05 Sonic Silver Burgman 650 project
'03 Space Blue Burgman 650, rebuilt/upgraded CVT w/Polish adapter
'03 Space Blue Burgman 650 parts bike

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