Friday, July 6, 2012

Reassemblng the Phoenix K2B.... Task outline

I had wanted to do some cleaning, polishing and brightening while the bike was partially apart. The one problem I'm having is that with all the aluminum on the bike I don't know what is dirt, stain, or pitting. I have no experience with this kind of aluminum. I looked at some engine degreasers, they are spray on applications and then wash down. With the bike apart and unsealed I felt this would be a bad thing to do. I'm just going to go ahead and put the bike back together and tear it back down for a good cleaning.

I'm doing this as an outline because I find that if I make a list things will come to mind that I might otherwise forget. Also, by spending time between entries I'm able to add things I've missed. With any luck, some folks may read this and add information I might have forgotten.

Re-assembly Task Outline
  1. Choke cable installation
    1. Use messenger line to run from top to bottom (pointy end flows better)
    2. Attach lower connection to throttle body
    3. Attach upper connection to chock lever at handlebar
    4. Test prior to attaching cap
      1. Grease if needed
      2. WHAT GREASE?
    5. Attach cap
  2. Throttle cable installation
    1. Use messenger line to run from top to bottom
      1. Attach lower connection to throttle body
      2. Attach upper connection to handlebar
        1. Test
        2. Adjust with adjuster if neccesary
      3. Attach cap
  3. Re-Attach Brake Resevoir
  4. Adjust and tighten handlebar
    1. Adjust to sharpie marks on handlebar
  5. Attach fuel pressure regulator
    1. Attach and clamp aft section of new hose
    2. Attach and clamp fwd section of new hose
    3. Attach and clamp new vacuum hose to bottom of regulator
  6. Attach newly painted fuel rail
    1. Flush painted rail with alcohol
    2. Check injector cups for paint
      1. Sand or brush as needed
      2. Blow out cups and rail
    3. Install new O rings on injectors
      1. Test for fit in cups
    4. Install electrical connectors to injectors
      1. Check bike side connectors for insulator
      2. Wire tie electrical leads to rail
      3. Bolt rail to bike
      4. Connect and clamp new Fuel hoses forward and aft
  7. Connect and clamp new crankcase breather tube
  8. Connect and clamp forward vacuum tube from fuel pressure regulator
  9. Connect and clamp aft vacuum tube from fuel pressure regulator
  10. Connect under tank electrical connections
    1. Check schematic against the electrical connections
    2. Count schematic
    3. Count under tank connections
  11. Check and confirm all undertank electrical connections
    1. Watch videos of electrical disconnects
  12. Check and confirm all uner tank electrical connections again
  13. Install Relay box cover
    1. Check for loose conections
    2. Check for tools and towels
  14. CONNECT BRAIN
  15. Install charged battery
    1. Confirm Positive and negative leads
    2. Ensure negative lead detached from bike body
    3. Attach positive lead to battery
    4. Attach negative lead to battery
    5. Check all electricals again
    6. ATTACH NEGATIVE LEAD TO BATTERY
  16. Install Fuel Tank
    1. Install and zip tie under tank overflow cup
    2. Attach and clamp fuel delivery hose
    3. Attach and clamp fuel overflow/return line
    4. Connect electrical connection to tank
      1. Confirm electrical connection to tank
    5. ?
Posted by at

No comments:

Post a Comment

Subscribe to: Post Comments (Atom)