DIY Network

Vintage Motorcycle Maintenance: Oil & Filters Change, Exhaust and Brakes From "Weekend Mechanic" episode WKM-304

	The 1978 Yamaha has new tires, seat-cover and exhaust system, has had essential scheduled maintenance and is now road-ready.
	Bruce and his assistant remove the front wheel in order to send it out for tire replacement.

In this segment of Weekend Mechanic, filters get replaced on the 1978 motorcycle, the old exhaust system is replaced with a new one and the brakes are serviced.

DIY Difficulty Rating for Repair: The repairs and service included here are fairly routine, and most can be found in the motorcycle's service manual. We gave it a difficulty rating of 2 on a 5-point intermediate-level scale. It took us about 8 hours, spread over two days, to complete the job.

Materials:

In addition to standard auto-mechanic's shop tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, etc.), some of the specialty tools that will be needed for this project include a motorcycle work bench, hydraulic brake-bleeder pump, torque wrench, milliliter measuring cup, and a motorcycle jack.

An air-compressor and set of pneumatic tools is optional, but may help speed the repair and maintenance process.

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Oil and Filter Change

• Next the engine oil and oil-filter can be replaced. The oil filter housing is held in place by a single bolt. Use caution when removing the bolt, and the oil-filter housing (figures A and B), as the oil-filter housing always full of oil.

  Figure A

  Figure B

  
  
• To install the new oil filter we first clean out the filter housing. Install the new filter (figure C) and fill the housing with oil before reattaching (figure D).

  Figure C

  Figure D

  
  
• Once the housing is reattached, add the new engine oil (figure E). This motorcycle takes about three and one half quarts of oil.

• Check to ensure the proper level using the dip stick (figure F)

  Important: Motorcycle engine oil should be changed every 3,000 miles.

  Figure E

  Figure F

  
  

• To change the air filter, remove the side covers from the air box (figure G), and remove the old filter.

• The old air filter on this motorcycle is an after-market substitute for the OEM (original equipment manufacturer) filter. We replaced it with an OEM filter (figure H, right).

  Figure G

  Figure H

  
  

  	Figure I
  	Figure J

• Now the new exhaust and muffler system can be installed to replace the old, rusted one (figure I). On the new system, the three exhaust pipes connect into a single collector pipe, instead of two pipes as on the old system.

• Install the pipes at the engine block by carefully positioning the pipes at the engine block (figure J) and securing the flanges.

• The muffler is then attached to the pipes and secured with a chrome clamp (figure K).
  

  	Figure K
  	Figure L
  	Figure M

• With the new front wheel back from the shop with a new tire, we reinstall the wheel back on the bike. Simply reverse the steps used to remove the wheel.

• With both wheels installed, we bleed the brake system. We use a brake fluid bleeder pump to vacuum out the old fluid (figure L). Open the bleeder valve on each brake caliper and allow the brake fluid to drain out. Once the old fluid has been drawn down into the bleeder reservoir, close off the bleeder valve.

• Fill up the brake fluid reservoir (figure M) and replace its cap.

• Important: Motorcycle brake fluid should be changed about every two years.
  

• Replace the gas tank and reattach the fuel and vacuum lines. When reattaching the lines (figure N) check them for splits or wear.

• With all other parts back on the bike, our final step is to reinstall the newly reupholstered seat (figure O). Reattach the seat by tightening the four bolts on the bottom side.

  Figure N

  Figure O

  
  Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

  Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools.
  

  
  

  RESOURCES :
  
  The Complete Idiot's Guide to Motorcycles
  ISBN: 0028624165
  Author: editors of Motorcyclist magazine

  The Haynes Small Engine Repair Manual
  ISBN: 1850106665
  Author: Curt Choate, John H. Haynes
  Haynes Publishing Group
  

  ALSO IN THIS EPISODE:
  	Vintage-Motorcycle Maintenance: Removing the Wheel and Seat-Cover
  	Vintage-Motorcycle Maintenance: Exhaust Removal and Cam Gasket
  	Vintage-Motorcycle Maintenance: Changing Fluids
  	Vintage Motorcycle Maintenance: Oil & Filters Change, Exhaust and Brakes