What I think I'm going to need

After getting the bike running the other night, I started making mental notes of what I'm going to need to get the XJ road worthy.
If I miss anyhing that you guys think I should check/replace, let me know.

Going to need to tune it up, so plugs and an oil filter.

I should replace the tires and brakes just because it has sat for unknown number of years.

The springs on the rear shocks are all rusty, and they be removed so I can blast them? Or should I get another set?

Head light needs a new ring, I need the starter button(found the link to them)

Needs a new front brake lever, I'm not sure how the master cylinder is, as I can't move it with the short piece that is left of the handle. I did pull the cover and it is full and looks clean inside.

Tach cable is broken about 2" back into it, so I need that. Alos need the bulb for the license plate light.

What else should I double check or purchase to make sure this is safe?

 

Check every fastener to make sure nothing important is loose.

 

Air filter, also check the choke, clutch, and throttle cables. Hows the fuse box look?

 

Dont forget the blinker fluid!

Riding gear is a must, a little spill in shorts and short sleeve shirt... I've heard they get the gravel out with brillo pads.

Maybe fasten/unfasten electrical connectors all over the bike, or use a cleaner on them. Might help prevent eletrical problems/bugs with the normal vibration of riding after sitting for so long.

Make sure you check the cotter pins and the bolts after your tires are changed.

 

Fuse box I did, But the other cables I'll check.
I did forget about the air filter. Thanks

 

Huh? :?

Good Idea on checking and cleaning all the connectors

 

Don't forget that you need to change both engine oil AND gear oil in that bike. Oil filter requires rings, at least for the first change. Maybe once a year after that. Spark plugs. Brake fluid (it's cheap, so change it), and brake pads. Brake lines, if there is ANY doubt about them. Replace them with steel braided lines if you can afford it. Check the rotor's thickness and deflection. (Bike shop here did it for $20 for two wheels.) New tires!

As someone else mentioned, check all of the electrical connections and that everything works as you expect (don't forget the kill switch, horn, self-cancelling unit, etc.). Flip on the high beams. Does the dash light come on? Neutral light? (Check all the instruments.) As someone pointed out to me not too long ago, the oil light should only come on when cranking the engine unless there's trouble. Just make sure it comes on, since that's kind of an important indicator!

Get out a multimeter and check the diode block inside the headlight. Indicators don't work if those are fried. Check the diodes in the rectifier. Start the bike and check the voltage output of the regulator (Haynes manual gives details). This keeps you from ruining batteries!

Oh yeah. Consider a new battery, if you haven't done that already. You're already checking out the suspension. Lube the hinges on both stands. Brake grease on brake caliper pivot bolts. Moly or lithium grease on the axles. That'll give you the excuse to replace those cotter pins, verify that ALL of the spacers are there, and that the various bolts that hold the axles are properly torqued.

Which reminds me: loosen and re-torque the bolts that hold the fork tubes. Some people really torque the crap out of those, for some reason.

Other than that, it's looking for trouble. Leaky petcock? Gaskets? Oil inside the alternator cover? Carb boots? Rubber boots that hold on the side covers? (Believe me, you'll lose 'em.) Plug wires and boots have the correct resistance? Most of those things come with obvious trouble signs, but you might as well go over everything...

And above all else... CLEAN IT. Seriously. It's MUCH easier to find and diagnose leaks on a clean bike.

 

Amen Brother Rhys! Testify!

 

Heh. We'll see if it's worth anything in the next 12 months, what with all the work I have set up for me with my three XJs...