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Checklist for "Waking up" long-sleeping Airheads

Posted: Tue Apr 08, 2014 5:06 pm
by John0313
Does anyone know of, or can they point me to a checklist for re-animating airheads that have been left dozing for 5-10 years or longer? I realize some things will be specific to /2s, and /5s, but the /6 and /7 series should be somewhat close. I know the typical things are:

Before Starting (or trying to!)

Dump gas tank, clean out varnish
Replace fuel lines
Clean out and/or Rebuild Carbs - Set needles, idle mixture, etc. to factory settings
Dump oil pan, clean out the sludge, new gasket
New oil filter
Drain/replace all other fluids
Plan on rebuilding master cylinders, brake calipers
Check Brake pads
Lube Final drive splines
Lube Transmission splines
New tires/tubes
Check torque on cylinders
Set Valves
Check Timing
New Battery
New (and proper) spark plugs & wires/caps
New Air filter
Check electrics (headlight, horn, brake and turn signals)
Check cables (throttle, clutch, brake)
Fresh Fuel

If she starts/runs:

Start slow, check brakes
Check operation of forks/shocks
Synch carbs after warm up
New oil and filter after 30-50 miles

What have I left out?

Lots to read here, although

Posted: Tue Apr 08, 2014 5:11 pm
by schrader7032
Lots to read here, although not necessarily geared towards "waking" a bike up:

Here's another list of scheduled maintenance items; probably good to look at and see what applies:

There are some Airhead related videos on this youtube channel, although you kind of have to not listen to some of the rough language: ... nch/videos

After looking through your

Posted: Tue Apr 08, 2014 5:14 pm
by schrader7032
After looking through your list, I'd add to the list the steering stem bearings if you feel any notchiness when turning the bars left or right as it passes through center. Also, the swingarm bearings will probably need a shot of grease.

Thanks. I thought about

Posted: Tue Apr 08, 2014 5:41 pm
by John0313

I thought about pulling the jugs for new pushrod seals and piston rings as well, but when I get it running, I'll find out soon enough if I need to go there!