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 Post subject: My Uly 10k service
PostPosted: 06 May 2013 19:41 
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proff. patpending
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Joined: 06 May 2009 20:20
Posts: 14705
Current ride: Victoria Sponge
Location: Bristol - Gateway to all things good
My Uly has just come up to 10k, so I thought I would treat it to a proper service.

I made a list of additional stuff, over and above the manual, to run past Maz.

1. Replace headraces
2. Replace wheel bearings
3. Replace swinging arm bearings
4. Replace tensioner bearings
5. Lubricate cables (I know it says this already but run oil down them)
6. Change brake fluids
7. Clean IAT sensor
8. Check ignition lead for chaffing
9. Check harness for chaffing
10. Clean wiring loom and connectors
11. Apply silicon grease to 77 connector
12. Clean throttle tube
13. Clean and lubricate brake and clutch pivots
14. Clean and lubricate gear lever and rear brake pivots
15. Clean throttle plate
16. Clean and lubricate tickover screw
17. Clean brake pistons (and sliders)

He gave me a bit of direction, but to be fair, a lot of what he would do is down to experience, knowing how to spot harness chaffing for example...

I started yesterday...

First of all to clean the bike. It does get cleaned, maybe not after every ride, and it gets coated in ACF50 or FS365 when I am feeling lazy, the former being the better. So, after a trip to see Maz on Saturday, and getting caught in the rain a few times as I crossed the Peak District, it was looking a little dirty...
Image

As it cleaned up, the extent of all weather 10,000 miles of corrosion was evident:
Image Image

A bit sad, but hey, time to treat it like a princess... :D

So, rear wheel came off and tensioner came off. Bearings in the tensioner were replaced (see How To), a pair of 6203s. Were they worn? Yeah, there was play in them, and as a Free Spirits tensioner is fitted, there is not a lot of margin for wear before the wheel starts to rub against the fork. There was a little bit of evidence that this had happened, but the anodising was pretty much in tact. You could feel movement in the wheel, as a result of play in the bearings, though.
Image

I also changed the wheel bearings, hence the input into the wheel bearing thread yeaterday. They were about 5000 miles old and were quite lumpy.

That was enough for yesterday, it is amazing how long these jobs take.

So, this morning, up at Dawn's crack, quick coffee at the local caf, then to work... Firstly, screw some door handles to the joists, start the oil draining into my big HD drain pan then hoist the bike up with tie-downs and off with the swinging arm...
Image Image Image

Bearings pulled and then replaced (6204s for all you :mrgreen: s)...
Image

Did the bearings need replacing at 10k? Well, I am glad I did replace them. There was more wear on the LH side than the RH, however it was noteicable on both sides. Of course, I didn't really have a problem with handling caused by these bearings being worn, but I guess it is one of those things that happens gradually and you don't notice it, just like headraces, which when changed make quite a difference to the ride.

Before fitting the bearings, I had to clean up on the non-drive side as there was some crap and corrosion near the bottom of the bore, I did this with my Dremel and brass Action Man chimney brush :D
Image

A quick look at the drain plugs (primary and engine - both a bit blurred) suggested all was in order:
Image Image

Then, next job was the 77 connector:
Image

Which didn't actually look too bad, however I filled it with Silicon grease to protect from corrosion. I had done this already once before...

Next job was the oil pressure switch, embarrasingly I have not had a functioning oil light for about 2000 miles :oooops:

I assumed it was the switch, and I kinda hoped it would start working the more I used the bike :run: , however that was not the case.

On an XB it is a PITA to get to, you need to move an oil pipe to get access:
Image

...but when I got access, I pulled the connector and tried to earth it and make the light come on, it wouldn't. I checked continuity to earth on the switch and it was earthed, so that pointed to a bulb failure or harness fault, however looking carefully at the connector, it looked like the harness had been pulling at it and had broken all the strands of wire... :?

I cut it back, and soldered on a longer bit of with with a bullet connector, used some heatshrink and some normal harness tubing to make the singe wire a bit more robust before connecting it back and clipping with cable ties away from the exhaust.

The primary drive was filled up with Fuchs V Twin 80/90, interestingly this comes in a 1L bottle, wherease the primary needs 1 quart, about 5% less, so I'll need to check the level...

Not filled the swinger oil tank up yet as I was wondering whether to use the Putoline Formula V Twin 20/50 I got free with my last set of Maxxis tyres... A quick read of the spec sheet says I will...

Still lots to do, maybe do a bit more tonight, but deffo will be onto it tomorrow night focussing on the front end...

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 Post subject: Re: My Uly 10k service
PostPosted: 06 May 2013 19:54 
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proff. patpending
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Joined: 06 May 2009 20:20
Posts: 14705
Current ride: Victoria Sponge
Location: Bristol - Gateway to all things good
Should have said, one of the great things about a deep service is the opportunity to Copaslip all the fasteners you are removing. There were a few that didn't want to come out, a few on the swinging arm brace and some of the screws holding the hugger and belt guard on. One of these I had to clean out with a tap. Better to ensure they come out when you need them to...

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 Post subject: Re: My Uly 10k service
PostPosted: 06 May 2013 20:30 
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Nanny Brown
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Joined: 23 May 2009 22:22
Posts: 6177
Location: Portsmouth, UK
:clap: :clap: Big respect to you for doing all your own work. I wouldn't even contemplate changing the colour of my bike let alone half the work you have undertaken. :4roz:

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Black P3 Blast - serviced by Maz and fixed by Maz in 2019


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 Post subject: Re: My Uly 10k service
PostPosted: 06 May 2013 20:37 
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Joined: 10 May 2009 18:19
Posts: 37
Current ride: Uly and two Nortons
Location: Staffordshire and ex t'Antarctic
Nice one Pash, thanks for this post, especially since I now have my own Uly ;)


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 Post subject: Re: My Uly 10k service
PostPosted: 06 May 2013 22:40 
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Joined: 07 Nov 2011 18:10
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Current ride: Buell ulysses
Location: Telford
Hi pash
how did you remove the oil pipes from the swinging arm , do you have the special tool , or have you made one :?:

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 Post subject: Re: My Uly 10k service
PostPosted: 07 May 2013 05:27 
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proff. patpending
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Joined: 06 May 2009 20:20
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Current ride: Victoria Sponge
Location: Bristol - Gateway to all things good
barney wrote:
Hi pash
how did you remove the oil pipes from the swinging arm , do you have the special tool , or have you made one :?:

Small screwdriver to remove the clips and the pipes pull out... All in the manual...

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 Post subject: Re: My Uly 10k service
PostPosted: 07 May 2013 08:15 
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Current ride: Buell ulysses
Location: Telford
my manual (page 3-73) shows an "oil line remover (B-41623-B)" Tool, this going around the pipe and then inside the union then once turned expands the clip to allow the pipe to be pulled out .
I shall have to have a look again ,this time with a different pair of glasses , hopefully I can see the little clip to be able to remove with small screwdriver . The joys and frustrations of getting older :old:

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 Post subject: Re: My Uly 10k service
PostPosted: 07 May 2013 08:26 
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proff. patpending
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Joined: 06 May 2009 20:20
Posts: 14705
Current ride: Victoria Sponge
Location: Bristol - Gateway to all things good
Yeah I saw that when I looked this morning. The page I looked at first just said remove clip, which I did... Careful it doesn't fly away when you pick it out.

O Ring part number 11110
Clip part number 11408

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 Post subject: Re: My Uly 10k service
PostPosted: 07 May 2013 08:32 
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Joined: 07 Nov 2011 18:10
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Current ride: Buell ulysses
Location: Telford
Hmm the old flying circlip record, quickly followed by hide and seek .

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 Post subject: Re: My Uly 10k service
PostPosted: 07 May 2013 10:06 
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Moderator
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barney wrote:
Hmm the old flying circlip record, quickly followed by hide and seek .



Oh yes lOl lOl lOl Have you seen my speaker magnet on a stick :?: ;) :headbang: lOl

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 Post subject: Re: My Uly 10k service
PostPosted: 07 May 2013 22:03 
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proff. patpending
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Joined: 06 May 2009 20:20
Posts: 14705
Current ride: Victoria Sponge
Location: Bristol - Gateway to all things good
Filled the swinger with oil last night as well as pulling the pads out of the rear caliper and cleaning the exposed parts of the pistons with WD40 and a tooth brush. I then cleaned the pads with brake cleaner.

Tonight, I jacked the bike up on the bottom of the engine and pulled the forks and then the headraces.
Image

I always wonder what people think of the mess in my garage...

I am sure the question everyone asks is; 'do I really need to replace my headraces at 10k?', well I wondered that, but after having them changed on the Firebolt at about 8k I instantly noticed a difference in the way the bike tracked.

The bearings from the Uly were rough and had quite a bit of play.

Instead of going for Buell bearings, I thought I would try some from Willy:
Image

I pressed them in using my threaded bearing puller...

Then on to the forks. More door handles screwed to the joists to let them drain...
Image

...into by big HD drainpan...
Image

My bike is an 06 model, but I fitted the later progressive springs from the 07 model - viewtopic.php?p=129935#p129935

These need a different air gap to the 06 springs.

Tomorrow is a busy day, so hopefully I will find time to reassemble the forks and get them refitted, then clean and inspect the disc mounting hardware, change the front wheel bearings and clean the caliper before putting it all back together.

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 Post subject: Re: My Uly 10k service
PostPosted: 07 May 2013 22:06 
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proff. patpending
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Joined: 06 May 2009 20:20
Posts: 14705
Current ride: Victoria Sponge
Location: Bristol - Gateway to all things good
Still to do:

2. Replace wheel bearings - Front only
5. Lubricate cables (I know it says this already but run oil down them)
6. Change brake fluids
7. Clean IAT sensor
8. Check ignition lead for chaffing
9. Check harness for chaffing
10. Clean wiring loom and connectors
12. Clean throttle tube
13. Clean and lubricate brake and clutch pivots
14. Clean and lubricate gear lever and rear brake pivots
15. Clean throttle plate
16. Clean and lubricate tickover screw
17. Clean brake pistons (and sliders) - Front only

Plus TPS reset, static ignition timing, spark plugs etc.

Feels like I have hardly touched it yet if I put all the time together, I have been on it over 14 hours...

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 Post subject: Re: My Uly 10k service
PostPosted: 08 May 2013 08:04 
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Joined: 07 Nov 2011 18:10
Posts: 4190
Current ride: Buell ulysses
Location: Telford
what air gap did you use in the end 172 or 192 :?:

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 Post subject: Re: My Uly 10k service
PostPosted: 08 May 2013 08:20 
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proff. patpending
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Joined: 06 May 2009 20:20
Posts: 14705
Current ride: Victoria Sponge
Location: Bristol - Gateway to all things good
I previously used 192 with no problems, but for this build they are still draining...

Interestingly, the forks have probably done 7000 miles and the oil looks well past its best, it certainly isn't 'clear' and has a 'metallic' effect...

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 Post subject: Re: My Uly 10k service
PostPosted: 08 May 2013 13:26 
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Joined: 07 Nov 2011 18:10
Posts: 4190
Current ride: Buell ulysses
Location: Telford
:shock: whats worn ( and how much ) to give you that " a 'metallic' effect..."

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