New Regulator New Horn Repairs and Maintenance

I've finally gotten around to installing the upgraded regulator and new horn in addition to some maintenance items. I noticed the fuel line had failed, so I replaced it with fresh fuel line. I repositioned the clutch cable correctly only to find that the bolt holding the lever arm at the engine is severely stripped. I also cleaned the air filter, which was in desperate need.

I was unable to reproduce the charging problem I had been noticing. It seems to be charging just fine right now.

LED Headlight Bulb Replacement - 36073

The low beam on the LED headlight bulb I installed in 2016 has failed so it needs to be replaced. Unfortunately, the lower mounting bolt for the headlight guard snapped so this project turned out to be much more involved than originally planned for. 

Road side battery replacement. - 35854

I broke my rule: “If there is any doubt there isn’t any.”

Battery failed and it wouldn’t bump start. Duncan went to get a battery and is on his way back.

Oil and Filter Change - 35854

Changed the oil and filter. Noticed a metal strand on the drain plug magnet. See Photo. 

2300 ml of Mobil 1 10w40 Racing GT. 

Front Wheel Bearings and Brake Pads in addition to an oil and filter change - 35684

While doing the fork seals, I checked the front wheel bearings and noticed that they did not spin freely so they need to go. In addition, the front brake pads are near their service limit so they need to be replaced and we're also coming up on an oil change interval so we might as well do that as well. 

Maintenance - Replace Tires - 32010

The Mefo Explorers on the DR have aged out. I was not able to find the correct sized Mitas tires so I just ordered the same MIssion Trail tires Duncan got. 

Maintenance - Replace Sprockets And Chain - 32010

On my Virginia Mapping trip, the chain, which was properly adjusted before I left, became so loose it started skipping over the sprocket teeth on acceleration. I'm fortunate that it did not come completely off. 

I'm going to go with the same set from Procycle that I used before with the smaller front sprocket. See the parts tab. 

Cam Chain Tensioner Gasket Replacement

The cam chain tensioner is leaking oil pretty badly. This is a common problem. According to some Youtube videos I watched, the old gasket can take quite some time to remove.

Gas Cap Venting Fix

The gas cap on the Mule doesn't seem to vent correctly and occasionally causes the engine to stall forcing me to open the tank to release the vacuum. 

Regular Maintenance 29158

On tap for today: oil and filter change, and a chain adjustment. I'll do valve and plugs another day.

Mileage: 29158

Timing Cover Removal

The timing cover port is completely seized. This is a common problem on these bikes. Procycle sells a billet replacement but getting the original factory plug out is proving to be quite challenging.

Exhaust Header Bolts and Gasket Replacement

During our last ride, both exhaust header bolts fell out towards the end of the ride. Hopefully, I have not burned up the valves.